Fastener, installation tool and related method of use

ABSTRACT

A fastener installation tool including a guide that guides a fastener into a side of a work piece at an angle, while optionally restraining the fastener from wobbling due to rotation, even upon initial entry into the work piece. The guide can define an angled bore including a fastener entrance opening and a fastener exit opening which is adapted to be positioned immediately adjacent the work piece. The guide can include a material ejection port between the openings, through which material bored from the work piece can be evacuated from the angled bore to prevent binding of the material with the fastener. The tool can include a clamp assembly that clamps opposing sides of the work piece to precisely align and steadily hold the angled bore as a fastener is being installed in a side surface. Related methods of using the tool to install fasteners also are provided.

BACKGROUND OF THE INVENTION

The present invention relates to fasteners, and more particularly to aside angled fastener, an installation tool and a related method of use.

There are a variety of commercially available fasteners that aredesigned to fasten a work piece, such as a wooden board or a compositeelement, to a substrate, such as a subfloor, joist or other underlyingsupport structure. In many cases, these fasteners are in the form ofthreaded screws including: a large, bugle-shaped head to which aninstallation drive attaches (for example, a Phillips or star drive screwhead); a shaft that projects from the head; threads on the shaft, and aconical, sharpened point, which centers the screw on a location, andinitially pierces the board so that the screw can advance into it. Thesetypes of screws are typically drilled downward, in an orthogonal manner,into the top of a board to fasten the board to an underlying support,such as a joist. Most of the holding power of such screws come from thebugle-shaped head engaging the board.

Another type of screw includes the above features, that is, a large,bugle-shaped head that provides holding force, and a threaded shaft.However, instead of a sharpened conical point, these screws include apoint having surfaces that meet at an acute angle between 15° and 35° toform a point. The acute angle of the surfaces enables the screw point todrill into a wood structure. While the acutely angled surfaces of such ascrew can pre-drill a hole for the screw, the acutely angled surfacesalso rapidly cut or drill into the wood. Accordingly, as soon as thefirst full threads engage the wood, they begin to quickly advance orfeed the screw into the wood. This rapid advancement, caused by thethreads twisting and subsequently thrusting the screw forward, sometimesleads to inadvertent splitting of the wood via a wedging action of theshaft and threads in the wood.

Recently, there have been developments in construction techniques andfastener technology that attach boards to a subfloor or underlying joistwith screws, but that attempt to conceal the heads of those screws. Thisis achieved by advancing the screws at an angle through the sides of theboards, rather than the exposed upper surface or tops of the boards, andsubsequently into an underlying support structure. When boards areplaced side-by-side one another, these “side angled screws” arerelatively unnoticeable by an observer looking straight down at theboards. Of course, at an angled view of the board, where portions of thesides of the boards may be visible, the screw heads may be somewhatvisible, but usually not overly conspicuous.

An issue with conventional side angled screws concerns theirconfiguration and the manner in which they advance into a work piece.Side angled screws typically include a conical, pointed tip. As soon asthis pointed tip penetrates the board, the screw threads bite into theboard, and rapidly draw the screw into the side of the board. As thisoccurs, the screw shaft is drawn between the grains or fibers or piecesof the board (depending on whether the board is constructed from wood ora composite). The drawing of the shaft between the grains or fibersfrequently causes the lower corner of the board to splinter from theremainder of the board (if wooden) or to bulge out the lower corner ofthe board (if composite) due to the wedging action of the shaft andthreads in the corner. Thus, conventional side angled screws can tend todamage the corner of the board into which they are advanced,particularly if they are imprecisely positioned or angled, or advancedtoo quickly into the board, or if the board is weak or dense. Typically,this will reduce the holding strength of the screw, which of course, isundesirable. Accordingly, there remains room for improving suchfasteners.

To compliment side angled screws which include conical, pointed tips,certain tools have been developed to facilitate their installation.Generally, these tools include a jig, with a plate that sets atop aboard to be fastened down, and a bore guide that generally aims thescrew toward the side of the board into which the fastener is advanced.One specific tool includes a jig body that rests atop a board, a handle,and pins that extend downward from a flat bottom of the jig body, andthat are configured to be positioned adjacent opposite sides of theboard. The pins also position the fastened board a distance from thenext adjacent board. The jig body bore guide is disposed at an angle,and generally aimed at a location that is intended to correspond to theside of a board. The bore, however, is located a distance away from theside of the board, generally above the pins, and terminates at thebottom of the jig body. Because the bore terminates at the jig body, itsend is located above the upper or top surface of the board, which is agood distance from the location where the tip first engages the side ofthe board.

While this tool can be used to install pointed end screws, it sufferssome shortcomings. For example, because the bore guide is distanced fromthe side of the board, screws advanced through the bore sometimes areplaced improperly relative to the lower corner of the board.Accordingly, when the screw is advanced, it can split off the lowercorner of the board. Further, if the tool is not perfectly aligned, thepointed tip of the screw sometimes can grab and pull the screw into theboard at an undesirable angle, which can cause the screw to bind againstthe bore of the jig body and slow its advancement, or cause additionalwear and tear on the guide.

In addition, while the pins of the aforementioned tool can help locatethe bore guide, those pins can also be a detriment. For example, theboards usually used in projects are of varying widths. The pins of thetool are joined with the jig body in fixed positions. Sometimes, thespacing between the pins is such that it does not match the varyingwidths of the board. Accordingly, the tool might not fit properly oversome overly wide, “outlier” boards in a particular project.Alternatively, where certain boards are overly narrow, the tool mayimproperly align the bore guide too far from the side of the board, sothat the screw misses the board or splinters off its lower corner.

While conventional side angled screws and installation tools exist,there remains an long felt need for improvements to both the screws andthe tools to better fasten down boards and other items with fastenersdriven through the sides of the boards in a manner that generallyconceals those fasteners.

SUMMARY OF THE INVENTION

A fastener including an end that pre-bores a hole for the remainder ofthe screw is provided. This fastener can be in the form of a screw thatcan be easily and consistently used in screwing operations where thefastener penetrates a surface of a work piece, such as a board or otherbuilding material, and optionally fastens the work piece or material toanother work piece, article or underlying support structure.

In one embodiment, the fastener can be a screw, for example, a sideangled screw, including a head attached to a body. The side angled screwcan be adapted to be advanced into the side of a board at an angle. Thehead can include a drive feature that mates with a corresponding drivetool. The body can include a shaft, threads and an end.

In another embodiment, the screw can include an end that is generally“V” shaped. The end can include a chisel edge or point that is adaptedto engage and scrape a surface of a work piece. Inclined surfaces can beopposed to one another across the chisel edge.

In yet another embodiment, the inclined surfaces can be disposed at anangle relative to one another, the chisel edge and/or a work piece intowhich the screw is advanced. Optionally, the inclined surfaces can beinclined at a negative rake angle when the end is engaged against a workpiece. Further optionally, the inclined surfaces can be disposed at anobtuse angle relative to one another, for example, greater than 90° butless than about 180°, or about 135° to about 170°. Even furtheroptionally, the inclined surfaces can be inclined at about 90°±10°relative to one another.

In still another embodiment, the screw end can be configured to scrapematerial from a work piece to pre-bore a hole for the remainder of thescrew. Where included, the threads can auger the scraped material outfrom the hole to ensure there is sufficient room for the remainder ofthe screw to enter the hole without splitting or otherwise damaging thework piece adjacent the hole.

In even yet another embodiment, the screw end can include a thread thatmerges with at least one of the inclined surfaces associated with thechisel edge. The thread can include a leading portion that is located ator near the inclined surface, and that extends outwardly from an axis ofthe screw. The leading portion can engage and move chips or othermaterial generated by the scraping action of the screw end, andsubsequently auger that material up, along the thread. The leadingportion optionally can form an extension of the chisel edge, with thethread beginning immediately adjacent the chisel edge.

In still yet another embodiment, the screw end can include a chiselbrake point having at least two inclined surfaces disposed at an anglerelative to one another. The screw end can act as a brake to retard thefeed or advancement of the screw into a work piece for a preselecteddistance. Optionally, the braking action of the chisel brake point canbe partially or fully overcome by threads on the screw engagingsurrounding material of the work piece, where the threads eventuallyimpart a forward advancing or feed force on the screw. When this occurs,the screw feeds or advances into the work piece at a faster feed rate.

In a further embodiment, the screw end including the chisel brake pointcan be configured for use with a screw that fastens a first work pieceto a second work piece. The chisel brake point can retard advancement orfeeding of the screw at least partially through the first work piece.When the screw has advanced into the first work piece a preselecteddistance, and optionally through the first work piece, the threads ofthe screw can engage the first work piece and increase the feed rate ofthe screw. Accordingly, the rate of advancement of the screw can change,due to the configuration of the screw (rather than a change in speed ofa tool rotating the screw), with the braking action of the chisel brakepoint being reduced, and the rate of screw feed increasing in the firstand/or second work piece.

In yet a further embodiment, a method is provided for using the screwincluding: providing a screw including a threaded shaft and an end, theend including a chisel edge and opposing inclined surfaces; constrainingall but rotational and axial movement of the screw; engaging the screwagainst a work piece; rotating the screw so that the end scrapesmaterial from the work piece surface; continuing to rotate the screw sothat the end pre-bores a hole in the work piece into which the remainderof the screw enters; and continuing to advance the screw into the workpiece, with the end continuing to scrape material from within the holeand the threads of the shaft augering the scraped material to ejectmaterial from the hole.

In still a further embodiment, a method is provided for installing afastener, for example, a screw having a shaft, threads disposed on theshaft, and a chisel brake point located at an end of the fastener, intoat least two work pieces. The method can include engaging the first workpiece with the chisel brake point; advancing the fastener into and atleast partially through the first work piece; retarding the advancementor feed rate of the fastener into and at least partially through thefirst work piece with the chisel brake point for a preselected distance;sufficiently engaging the threads of the fastener with the first workpiece after the fastener is advanced the preselected distance, where theengagement of the threads increases the feed rate into and through atleast one of the first work piece and the second work piece. Optionally,the engagement of the threads with the first work piece generates anadvancement or feed force that is greater than a braking force of thechisel brake point, which braking force retards the feed of thefastener.

In still yet a further embodiment, an installation tool is provided. Thetool can include a handle, a frame, and a tool screw guide or pilotelement defining a screw bore that aligns a screw with a desiredlocation on a work piece. The screw guide can prevent the screw fromexcessively wobbling as it rotates in the screw bore, relative to thework piece, so that the screw can be started in the surface of the workpiece and advanced satisfactorily.

In another, further embodiment, the tool screw guide can include aspacer that extends downwardly from a body of the guide, and that sets agap between adjacent boards or other construction materials joined withan installed screw. The screw bore can be defined at least partiallywithin the spacer, so that the end of a screw is positioned andcontained immediately adjacent the surface into which it is to beadvanced.

In yet another, further embodiment, the tool guide can include aclamping mechanism that clamps the tool in place relative to a board orother construction element into which a screw is to be installed withthe tool. The spacer can be a part of the clamping mechanism, and canmove relative to the frame of the tool. The tool can include anotherspacer element distanced from the screw guide spacer. The distance cangenerally correspond to a width of a board or other constructionelement. The distance can be changed by moving the spacer relative tothe spacer element sufficiently to clamp the board between thesecomponents. Accordingly, a screw installed with the tool can beprecisely advanced into a surface of the board or other constructionelement.

In still another, further embodiment, the screw guide can include amaterial ejection port in communication with the screw bore. With thisport, material scraped, extracted and/or removed from the hole producedby the screw can eject from the port, thereby preventing or impairingthe material from hindering screw rotation within the tool.

The fastener described herein provides a simple and efficient structurethat can pre-bore a hole for itself as it is advanced into a work piece.The fastener can be a screw that is easily advanced into a work piece atany angle, but optionally, the fastener is well suited to be advancedinto the side of a work piece so that when installed, it is generallyconcealed from view from a viewer directly above the work piece. Whereincluded, threads of the screw can auger material scraped by the screwout from the hole bored by the screw to promote efficient advancement ofthe screw and/or to prevent damage, such as splitting, of the work pieceadjacent the hole and/or screw. Where included, the chisel edge brakepoint can selectively retard advancement or feed of the screw to preventdamage, such as splitting, of the work piece adjacent the hole and/orscrew.

Further, the installation tool described herein can easily andconsistently align a fastener with a desired surface of a work piece,and efficiently contain that fastener as it is rotated to preventexcessive wobble. The installation tool also can be securely andprecisely joined with a work piece where it includes a clampingmechanism. This can promote accurate advancement of the fastener intothe work piece. In addition, when a material ejection port isincorporated into the tool, it can facilitate dumping of material boredby the fastener out from a screw guide, which can prevent clogging ofthe guide, and impairment of fastener rotation.

These and other objects, advantages, and features of the invention willbe more fully understood and appreciated by reference to the descriptionof the current embodiment and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a current embodiment of a fastener;

FIG. 2 is a second side view of the fastener;

FIG. 3 is a third side view of the fastener;

FIG. 4 is an end view of the fastener;

FIG. 5 is an enlarged side view of the end of the fastener engaging awork piece;

FIG. 6 is a side view of the fastener engaging a work piece;

FIG. 7 is a first side view of the fastener being initially installed ina first work piece;

FIG. 8 is a second side view of the fastener advancing into the firstwork piece;

FIG. 9 is a third side view of the fastener as it further advances intothe first and second work pieces;

FIG. 10 is a fourth side view of the fastener as it is fully advancedinto the first and second work pieces;

FIG. 11 is a chart illustrating the feed rate of the fastener into workpieces over time;

FIG. 12 is a side view of a first alternative embodiment of thefastener;

FIG. 13 is a second side view of the first alternative embodiment of thefastener;

FIG. 14 is a third side view of the first alternative embodiment of thefastener;

FIG. 15 is an end view of the first alternative embodiment of thefastener;

FIG. 16 is an enlarged perspective view of the first alternativeembodiment of the fastener;

FIG. 17 is an enlarged side view of the end of the first alternativeembodiment of the fastener engaging a work piece;

FIG. 18 is a side sectional view of the first alternative embodiment ofthe fastener installed in first and second work pieces;

FIG. 19 is an enlarged perspective view of a second alternativeembodiment of the fastener;

FIG. 20 is an enlarged side view of an end of a third alternativeembodiment of the fastener;

FIG. 21 is another enlarged side view of the end of the thirdalternative embodiment of the fastener;

FIG. 22 is a side view of a current embodiment of a fastenerinstallation tool;

FIG. 23 is an end perspective of the fastener installation tool;

FIG. 24 is a close up view of the fastener installation tool in useinstalling a fastener;

FIG. 25 is a side view of a first alternative embodiment of a fastenerinstallation tool;

FIG. 26 is a close up view of the first alternative embodiment of thefastener installation tool in use installing a fastener;

FIG. 27 is a side view of the second alternative embodiment of thefastener installation tool before being placed adjacent a work piece;

FIG. 28 is a side view of the second alternative embodiment of thefastener installation tool installed on a work piece;

FIG. 29 is a bottom perspective view of the second alternativeembodiment of the fastener installation tool;

FIG. 30 is an exploded view of the second alternative embodiment of thefastener installation tool;

FIG. 31 is an enlarged end view of the fastener guide of the secondalternative embodiment of the fastener installation tool;

FIG. 32 is a first side view of an adjustment element of the secondalternative embodiment of the fastener installation tool; and

FIG. 33 is another side view of an adjustment element of the secondalternative embodiment of the fastener installation tool.

DETAILED DESCRIPTION OF THE CURRENT EMBODIMENTS

A current embodiment of a fastener is illustrated in FIGS. 1-6 andgenerally designated 10. The fastener can be in the form of a threadedfastener, and more particularly, a screw 10 including a head 20 and ashaft 30. The head can include an upper portion 22 and a lower portion24. The upper portion 22 can be of a uniform diameter 23 (FIG. 3), whichcan range from about 0.197 to 0.202 inches in diameter, or can be ofother dimensions if desired. The upper portion 22 of the head can begenerally cylindrical and of a uniform diameter from the end of the headwhere the opening to the drive feature is located, to where the upperportion 22 begins to transition to the lower portion 24, where it tapersdown to the shaft 30 of the screw 10. Optionally, the lower portion canbe in the form of a frustoconical portion.

The upper portion 22 of the head 20 can define a screw drive feature,such as a star drive, a Phillips head drive or any other suitable drive.The screw drive feature can define a hole 26 in the head, and can becompatible with any suitable drive feature, as noted above. Optionally,the hole 26 can be generally in the shape of a six-pointed star. Thegeneric name of this type of drive feature is a star drive, orhexalobular internal drive feature, which is standardized by theInternational Organization for Standardization as ISO 10644. Oneoptional type of star drive feature is a TORX drive, which drive comesin a variety of sizes, generally designated by a “T” and some number,such as T-10, T-15, and the like. TORX is a trade name of Textron, Inc.of Providence, R.I.

The particular drive and size of the hole 26 of the head 20 can vary,but as shown, it can be a T-15 size. The dimension from point-to-pointof a T-15 hole in screw head can be about 0.128″. The maximum torquerange for such a head can be about 6.4 to about 7.7 Nm, as applied via acorresponding tool or head coupled within the hole. The hole 26 can beconfigured to accommodate a T-15 size TORX drive head. The hole 26 canbe quite large, and thus the material 29 between the points of the holeand the outer diameter 23 of the head around the hole can be of arelatively small dimension. In some cases, the material between theouter diameter and the outermost portion of the points on the hole 26can range from about 0.0325 to 0.035 inches. The hole 26 can be of adepth equal to, less than or greater than the depth 25 of the upperportion 22 of the head having the uniform diameter. Generally, the depth25 of the upper portion can range from about 0.055 to 0.065 inches. Ofcourse, where drive features, other than the optional T-15 drive areused, the dimensions of those features can widely vary depending on theapplication.

The drive feature can be connected to a rotary operated tool, such as adrill, that turns the head, and thus the screw 10, to advance the screwinto a work piece as described in detail below. Optionally, the screwhead can be of the same diameter as the shaft or smaller, or completelyabsent from the screw, with a drive feature simply included on ordefined by the shaft 30 opposite the end 50.

Referring to FIG. 1, the shaft 30 of the screw 10 can be relativelycylindrical. The cylindrical portion can include threads 40 whichprotrude from it and wrap or coil around it. The threads can continue tothe end 50 of the screw. Optionally, the threads can end or taper off apreselected distance from the end, for example 0.010″ to about 0.5″, orother distances as desired for the application. Further optionally, asdescribed in the alternative embodiments below, one or more of thethreads may be included in the end, possibly merging with and forming aportion of one or more inclined surfaces and/or the chisel edge. Evenfurther optionally, the threads 40 can extend from the head 20 to theend 50 of the screw, depending on the application.

The threads can be configured at a particular pitch to theoreticallyprovide a preselected feed rate of the screw into a work piece. Forexample, the threads may be pitched to provide a feed rate of about 1 toabout 8 millimeters per full revolution of the screw about itslongitudinal axis 200 (FIG. 5), also referred to as a screw axis. Otherthread pitches can be selected to provide other desired theoretical feedrates.

The threads 40 can end at a last thread 45 as shown in FIGS. 1-5. Thelast thread 45 can terminate at a leading portion 48, which can have athread height 49 (FIG. 2) that gradually decreases until it fades intothe generally cylindrical portion of the shaft 30. Alternatively,although not shown, the last thread 45 can terminate abruptly, with theleading portion of the last thread having a thread height that isgenerally the same as the threads located above it on the shaft. Withthis configuration, the leading portion can terminate at a flat, beveledor sharpened forward surface as desired. Optionally, the location of theleading portion 48, and thus the end of the last thread 45 can varyrelative to the chisel point 56. As shown in FIGS. 1-3, the leadingportion 48 can terminate and fade or merge into the shaft 30 before theinclined surfaces 52 and 54 begin at the end 50, or at some otherlocation relative to the inclined surfaces or chisel edge.

The leading portion 48 can end adjacent an apex of one of the inclinedsurfaces 54 as shown in FIGS. 3 and 5. If desired, however, the leadingportion can terminate much farther up the shaft, away from the inclinedsurfaces, toward the head. Alternatively, the leading portion canterminate farther along the shaft, generally adjacent one of theinclined surfaces. Further, the leading portion can terminate the lastthread somewhere between the opposing inclined surfaces 52 and 54,rather than at an apex or along some other portion of those surfaces.Other examples of the leading portion are presented in the alternativeembodiments below.

Returning to the end 50 of the screw in general, instead of beingsharpened to a conical point (as with conventional screws), it insteadcan include a chisel edge 56 which includes inclined surfaces 52 and 54diverging rearwardly from the chisel edge in a V-shaped configuration asseen in the side view of FIGS. 1, 4 and 5. The inclined surfaces 52 and54 can be at a variety of angles relative to the longitudinal axis 200,for example 25°, 35°, 45°, 55°, 65°, 70°, 80°, or any anglestherebetween that are suitable for the desired application. Optionally,the inclined surfaces 52 and 54 can be inclined at the same or differentangles relative to the longitudinal axis 200.

Further optionally, the inclined surfaces 52 and 54 can be disposed atan obtuse angle α relative to one another as shown in FIG. 5. The obtuseangle can be any obtuse angle greater than 90° but less than 180°.Nonlimiting examples of ranges of suitable obtuse angles can have alower limit of about 91°, 95°, 100°, 105°, 110°, 115°, 120°, 125°, 130°,135°, 140°, 145°, 150°, 155°, 160°, 165°, 170°, 175°, and 179°; and acorresponding upper limit of 179°, 175°, 170°, 165°, 160°, 155°, 150°,145°, 140°, 135°, 130°, 125°, 120°, 115°, 110°, 105°, 100°, 95°, and91°. Several further exemplary ranges are between about 135° and about170°, between about 145° and 160°, and about 130°.

Although shown as generally planar elements, the inclined surfaces 52and 54 can include surfaces that are slightly curvilinear. For example,the inclined surfaces can be slightly concave or convex, or even wavy orserrated depending on the application. As a result, the chisel edgelocated where the inclined surfaces meet can likewise be curvilinear,for example, concave or convex. Where the inclined surfaces aregenerally planar, the chisel edge can be substantially linear.

As shown in FIGS. 2 and 4, the chisel edge 56 and corresponding inclinedsurfaces 52 and 54 can extend outwardly to an outer diameter 32 of theshaft 30. The inclined surfaces 52 and 54 can be diametrically andsymmetrically opposed to one another about the chisel edge 56, and/orthe axis 200. In such a configuration, the chisel edge 56 can lie alonga line that bisects the outer circumference of the shaft, and can be ofthe same length as the diameter of the shaft. As illustrated in FIGS. 1and 2, the chisel edge 56 can extend substantially linearly from oneside of the outer diameter 32 of the shaft 30 to the other side of thediameter 32 of the shaft 30, and/or in a transverse manner across amajority of the diameter of the shaft 30 in any desired location.

Optionally, the chisel edge 56 can be offset a preselected distance fromthe diameter of the shaft. In which case, the inclined surfaces 52 and54, while being opposed to one another across the chisel edge 56, mightnot be symmetric. For example, one of the inclined surfaces might be ofa larger surface area than the other. The chisel edge and the respectiveinclined surfaces, or generally the end 30, can be void of any cuttingedges that effectively cut into a surface of a work piece against whichthe end is engaged. Instead, as shown, the end can be configured toscrape the surface against which it is engaged when being advanced by atool, and to act as a brake to retard advancement or feed of the screwinto a work piece, as further explained below. Of course, depending onthe application, one or more true cutting surfaces might be incorporatedinto the end 50.

Generally, the screw end 50 can include a chisel brake point 59, whichas used herein, means that the end includes at least two inclinedsurfaces 52 and 54 disposed at an angle α relative to one another, wherethe end 50 functions as a brake to selectively retard advancement orfeed of the screw 10 into and/or at least partially through a workpiece. In some embodiments, the angle α can be about 85° to about 95°,optionally about 90°, further optionally an obtuse angle, and evenfurther optionally, any of the angles noted in connection with the otherembodiments herein. Further, although referred to as a “point,” theactual structure of the chisel brake point can include an edge, ratherthan a true point, that is formed at the intersection of the two or moreinclined surfaces. Optionally, the edge extends along a diameter, achord or other transverse dimension of the shaft 30 and or end 50 of thefastener 10.

One mode of operation of a specific embodiment of the screw 10 and itsend 50 will now be described with reference to FIGS. 5 and 6. Whenadvanced into a work piece 102, the screw 10 rotates in the direction ofthe arrow 101. With such rotation, the inclined surface 52 can form arake angle, specifically a negative rake angle X°, which indicates thatX° is less than or equal to 90°, which corresponds to the angle α being90° or an obtuse angle. Thus, when the screw 10 is rotated asillustrated by the arrow 101, the inclined surface 52 (having thenegative rake angle) and/or the chisel edge 56 forcibly scrapes thesurface of the work piece 102 due to drag and friction. As a result, thechisel edge 56 and respective inclined surfaces remove material 104 fromthe surface of the work piece 102 (or the bottom of the hole) via ascraping action. The amount of scraping can be increased or decreasedbased on the amount of force which is applied along the longitudinalaxis 200 by a tool or user.

On the opposite side of the chisel edge 56, the inclined surface 54 alsoforms a negative rake angle, which can be the same as or different fromthe rake angle X° of the inclined surface 52. This inclined surface 54and/or the chisel edge 56 can scrape and remove material 104 from thework piece as described in connection with the other inclined surface.

Generally, without a tool to hold the screw 10 on the fixed axis 200,rotation of the screw 10 and the chisel edge 56 may cause the screw 10to wobble uncontrollably against the work piece, making it difficult toadvance the screw 10 into and/or through a desired location on the workpiece. This can occur particularly in instances where the screw 10 isinstalled as a side angled screw, generally in a non-orthogonal mannerinto a surface of a work piece. Accordingly, an installation tool 70 asdescribed herein is suitable for installing the screw 10 in a variety ofwork pieces.

Advancement or feed of the screw 10 into a work piece 102 can be furtherunderstood with reference to FIG. 6. As shown there, with theconfiguration of the screw end 50, and in particular, the chisel edge56, the end 50 of the screw scrapes material 104 from the hole 103 whichcan be created by the scraping action of the end 50 within the workpiece 102. The material 104 subsequently scraped from the bottom of thehole 103 can be augered upward, or otherwise away from the end 50, bythe threads 40 a, 40 b, 40 c (which can be part of the continuous thread40) of the fastener 10 until the material is ejected from the hole,beyond the surface of the work piece 102.

Thus, in the embodiment of FIG. 6, the screw not only scrapes a hole inthe work piece 102, but also removes the material from the hole so thatthe screw in effect can be threaded into a pre-bored hole (pre-bored bythe screw end 50 and chisel edge 56) defined by the work piece. Thescraping action of the end 50 can prevent the shaft 30 and threads 40 ofthe fastener from advancing or feeding too quickly into the work pieceor otherwise advancing in a manner that will split the work piece intowhich it is drawn.

FIGS. 7-10 illustrate an example of a screw 10 of the current embodimentbeing installed in a first work piece 102 and a second work piece 102 tojoin those work pieces. Generally, the screw 10 joins the first workpiece 102, which can, for example, be a board, to a second work piece106, which can be a subfloor, joist or some other support structure.Also illustrated is the material 104 previously augered out from thehole 103 which the screw self-bored for itself. As shown in FIG. 10, thescrew 10 can be advanced into the board 102 a desired distance so thatthe head is not too conspicuous when viewed from above. The screw 10 canbe screwed into the side surface of the board at an angle β whichoptionally can be about 15° to about 65°; further optionally about 45°or any other desired angle. If desired, the screw can be advanced at anon-orthogonal angle to the surface of the board, or optionally an angleother than 90° relative to the surface of the board. Again, althoughshown connecting a board to an underlying joist, the screw 10 describedherein can be used in any application where it is desirable to use ascrew with a feature that pre-bores a screw hole with the screw itself.For example, it can be used to join corners of boards, used in cabinetryor as trim, particularly where the wood or other materials require apilot hole to be pre-bored before installation of a screw to preventsplitting, or simply to facilitate advancement of the screw into thework piece.

Further referring to FIGS. 7-10, a method of installing a currentembodiment of the screw will now be described in more detail. Asillustrated, the screw 10 includes a shaft 30, threads 40, a screw end50 and the chisel brake point 59. The screw 10 can be advanced through afirst work piece 102 and into a second work piece 106. As shown in FIG.7, the first work piece 102 is engaged by the chisel brake point 59 androtated in the direction of the arrow with a tool (not shown) joinedwith the screw head. A force F1 can be applied by a user to initiate thescrew in boring into the side of the work piece 102 at some preselectedangle β, which can be established by a user via an installation tool asdescribed below or some other type of guide or tool. The screw 10 can beadvanced into the work piece 102, and in so doing, the chisel brakepoint 59 can begin to scrape away material 104 from the hole 103 thatthe point creates in the work piece 102. The force F1, which istransferred to the screw 10 to bore the screw into the work piece 102,can be between about 1 and about 35 pounds, or more or less depending onthe application, the type of wood or composite, and the type ofinstallation tool.

Referring further to FIG. 7, the screw is advanced or fed at leastpartially into the work piece 102. During this advancement, the chiselbrake point 59 bores away material 104 to create the hole 103 into whichthe screw 10 advances or feeds. The chisel brake point 59, retards thefeed or advancement of the screw into the work piece 102, and generallyprovides a braking force to prevent the screw from being rapidlyadvanced into the work piece 102. In turn, this can impair and/orprevent damage to the material surrounding the screw 10, and canspecifically prevent and/or impair splitting of materials, for example,wood in the area in which the screw is advanced. As a more specificexample, the braking force can impair rapid advancement of the screwinto the work piece 102, which advancement would otherwise typically begenerated by the threads 40 engaging the work piece and thrusting itinto the work piece, to prevent a lower corner of the work piece 102from splitting off the remainder of the work piece. As shown in FIG. 8,the screw 10 can continue to be rotated, and fed into the work piece102, with material 104 continuing to be augured by the threads 40 outfrom the hole bored by the chisel brake point 59.

As the screw 10 advances into the work piece 102, the chisel brake point59 can act as a brake to retard or reduce the feed rate of the screw 10into the work piece 102 for a preselected distance 77. This preselecteddistance can be anywhere from ⅛, ¼, ½, ¾, 1, 1¼, 1½, 1¾, 2, 2½, or more,or less, inches. As shown, the preselected distance 77 is about ½ to ¾of an inch. Optionally, this distance can correspond to the distancebetween one surface 108 of the work piece 102 and a second surface 109of the work piece 102, so that the feed rate of the screw generally isslowed through a portion or all of the first work piece, which may bemore prone to splitting or damage.

Further, as shown in FIGS. 7 and 8, as the screw 10 advances, and thechisel brake point 59 acts to retard advancement of the screw into thework piece, the threads 40 also can engage the material of the workpiece surrounding the bore 103 bored by the chisel brake point 59.During such engagement, the threads 40 can rotate or move relative tothe sides of the bore 103 without substantially advancing the screw intothe work piece upon such engagement, or generally without the threadsthrusting the screw into the work piece at the theoretical feed rate forwhich the threads are designed. Optionally, this can contrast operationof conventional screws, where the engagement of the threads of thosescrews with the material surrounding the screw would typically lead tothose threads thrusting the screw into the work piece at the theoreticalrate of feed for which the threads were designed.

As the screw is advanced the preselected distance 77, shown in FIG. 8,the force F2 applied can be equal to or greater than the initial forceF1 applied to initiate advancement of the screw. Further, the screw canrotate about the axis anywhere from optionally about 10 to about 100rotations; further optionally about 15 to about 70 rotations; evenfurther optionally about 20 to about 50 rotations, yet furtheroptionally at least about 25 rotations, as it is advanced into the workpiece 102, until the head of the screw engages the work piece. This cancontrast a conventional sharp pointed screw, which typically might onlybe rotated about five to twelve times, depending on the number andcharacteristics of threads on the conventional sharp pointed screw. Thisalso can contrast the design of the threads of the screw 10. Forexample, the threads may be designed to advance the fastener into thework piece so the head engages the work piece optionally within about 10to about 20 rotations, further optionally in less than about 15rotations of the fastener about the axis. The additional rotations ofthe embodiments to advance the fastener to a desired depth herein, forexample, where the head engages the work pieces, can be attributed tothe braking action or force generated by the chisel brake point 59 atthe end of the screw, which slows or impairs advancement of the screwinto the material of the first work piece 102.

When the screw has been advanced into the work piece 102 the preselecteddistance 77, a number of the threads 40 sufficiently engage the hole 103which was pre-bored by the chisel brake point 59, and the materialsurrounding the hole of the work piece 102. Further rotation of thescrew 10 in the direction of the arrow causes the threads to overcomethe braking force created by the chisel brake point 59. Optionally, thisovercoming of the braking force can occur when the preselected distancegenerally corresponds to the dimension of the work piece in the areawhere the screw 10 penetrates or is otherwise bored through the workpiece 102. The engagement of the threads 40 with the hole 103 andsubsequent overcoming of at least a portion of the braking forcegenerated by the chisel brake point can increase the rate of advancementof the screw through the work piece 102, as well as the rate ofadvancement of the screw into and through a portion of the second workpiece 106. Accordingly, the braking force and subsequent retardingforces and action of the chisel brake point 59 is overcome a desiredamount so that the threads 40 advance the screw through the first workpiece and into the second work piece at an increased rate of feed.

Optionally, the screw then can begin to advance into the second workpiece 106. The rate of advancement or feed, when with the threadsovercome at least a portion of the braking force, can result in thescrew 10 being advanced or fed about 1, 2, 5, 7, 10, 12, 15, 20, 25, 30,35, 40 and/or 50 (or any range between or above any of theaforementioned values) times faster than when the braking force of thechisel brake point was retarding advancement of the screw. With thethreads 40 sufficiently engaging and advancing the screw into the workpieces, the force F3 in FIG. 9, and F4 in FIG. 10, applied to the screwcan be less than the forces F1 and F2 applied before with the brakingforce of the chisel brake point 59 was overcome by the forward thrustcaused by the threads 40.

As shown in FIG. 9, the screw 10 can be advanced into the first workpiece 102 and further into the second work piece 106. During thisadvancement, the chisel brake point 59 can provide a braking force, butmost, if not all, of it is overcome by the feeding force generated bythe threads 40 engaging the material surrounding the hole 103. Thechisel brake point 59 also can pre-bore a hole 103 in the second workpiece 106. Material 104 also can be augured out from the respective holecreated by the screw in the second work piece 109. Where theinstallation tools described herein are used to install the screw, thatmaterial can be ejected from a material ejection port as describedbelow.

With reference to FIG. 10, the screw 10 can continue to advance untilthe screw head 20 is sufficiently indented in or buried in the sidesurface 108 of the work piece 102. In some cases, the head of the screwis completely positioned in the hole 103, so that no portion of the headextends beyond the first surface 108 of the work piece 102. Optionally,the screw 10 can be advanced sufficiently so that it is at leastpartially hidden from a viewer “V” viewing the work piece generally fromabove. With the screw 10 installed as shown, optionally about 20% to100%, further optionally about 50% to 90% of the holding force F5 of thescrew 10 is provided via the screw shaft 30 and/or threads 40, ratherthan via the head 20 of the screw 10. Further, where screws 10 aresimilarly installed on opposite side surfaces of the work piece 102,with the screws generally pointing toward one another and embedded inthe underlying work piece 106, those opposing screws can cooperativelyprovide sufficient force to hold down the work piece 102, with asubstantial portion of the holding force being supplied via the shaft ofthe screws, rather than the heads of the screws.

Another feature of the screw of the embodiment herein concerns thechisel brake point 59 and its effect on feed of the screw. Optionally,the point 59 can include inclined surfaces that are at an angle relativeto one another so that they provide a sufficient braking force such thatthe screw does not feed or advance into the first work piece 102 at arate corresponding to the pitch of the threads 40 until after the chiselbrake point at least partially penetrates through the work piece 102,for example, a preselected distance 77, or through the second surface109 of the work piece. In such a manner, the screw can prevent or impairexcessive wedging of the threads 40 and/or shaft 30 through the materialof the work piece 102 surrounding the screw 10, thereby preventing orimpairing damage such as splitting to that material and thecorresponding corner edge of the work piece 102. With the screwsubstantially or fully penetrated through the first work piece 102, itsrate of advancement can change, and generally increase, so that itadvances at a faster rate into the second work piece 106. Of course, inso doing, the remaining portion of the screw in the first work piece102, including the shaft 40 and head 20, can be advanced in and/orthrough the first work 102 piece at a greater rate than the rate beforethe screw penetrated the second surface 109 of the work piece 102.

In the above described mode of operation, the feed rate of the screw 10into and/or through the work pieces also can change as the screw isadvanced or fed into the first and/or second work pieces 102, 106. Forexample, as the screw 10 is turned in the direction of the arrow in FIG.7, the feed rate of the screw 10 into the work piece 102 can be apercentage slower or less than the theoretical feed rate provided by thepitch and configuration of the threads 40. As a more specific example,the threads 40 can be configured to provide a theoretical feed rate ofone millimeter per one revolution of the screw 10. Due to the brakingforces provided by the chisel brake point 59, however, the actual feedrate of the screw 10 can be only 0.25 millimeters per one revolution ofthe screw 10. This braking force or action can retard advancement of thescrew, or otherwise reduce the feed rate of the screw for thepreselected distance 77 (FIG. 8). As more threads 40 of the screw engagethe material surrounding the hole 103 bored by the chisel brake point59, the braking force provided by the chisel brake point 59 can beovercome by the threads 40. The feed rate of the screw 10 can increasedynamically as more threads engage the material of the work piece 102,overcoming the braking force.

Thus, by example only, the feed rate of the screw into the work piece102, after the chisel brake point 59 has advanced a preselected distance77 into the work piece 102, can increase from 0.25 millimeters per onerevolution (which is caused by the braking force of the chisel brakepoint) up to 1.0 millimeter per one revolution, which again can be thetheoretical feed rate of the screw based on the pitch of the threads 40.When the screw 10 penetrates through the other surface 109 of the workpiece 102, it can be advanced at a feed rate of about one millimeter perrevolution. Accordingly, when it enters the second work piece 106 it canbe advanced at the full theoretical feed rate, or at some percentage,for example, about 70%, 80% or 90%, of the full feed rate.

In general, the feed rate of the screw 10 into the work piece 102 candynamically change from a first feed rate to a greater, second feed rateas the screw enters the work piece, nearing the preselected distance 77.This can occur because additional threads 40 of the screw 10 begin toengage the material around the hole pre-bored by the chisel brake point59. As more threads engage the work piece 102, the forward force/thrustprovided by those threads begins to overcome the braking force providedby the chisel brake point 59.

The aforementioned mode of operating the fastener 10 of the currentembodiment and screw features also yields a suitable method forinstalling a fastener to join a first work piece with a second workpiece. In this method, a fastener 10 is provided. The fastener can bethe screw of any of the embodiments herein, having a chiseled brakepoint 59 and threads 40, where the threads are configured to advance thefastener 10 at a first feed rate, which for the sake of this example,can be a theoretical feed rate. The fastener 10, and in particular, thechiseled brake point 59 can be rotated and brought into engagement withthe first work piece 102 as it is rotated. Initially, the chiseled breakpoint can penetrate the side surface of the work piece, as generallyshown in FIG. 7.

Optionally, the screw 10 can be held with an installation tool at apreselected angle, and generally aimed at the angle β at the sidesurface 108 of the work piece 102. The installation tool can also engagethe head or other portions of the screw to rotationally restrain thefastener as it is advanced, and generally to prevent or impair excessivewobble of the screw in so doing. In general, the installation tool orsome other driver, such as a drill, can rotate the fastener.

The fastener 10 can be advanced into the first work piece 102 at asecond feed rate, less than the first feed rate, due to the chisel brakepoint 59 retarding advancement of the fastener 10 into the work piece102 and providing a braking force that reduces the first feed rate ofthe fastener into the work piece to the second feed rate, or moregenerally impairing the fastener from increasing its feed rate to thetheoretical feed rate of the screw 10.

Returning to the method, the chisel break point 59 can pre-bore a holein the first work piece 102 and the second work piece 106. When thefastener is advanced so that it extends through the first work piece andengages the second work piece, the hole 103 generally is completelybored through the first work piece. The diameter of that hole 103 can beabout the size of the widest diameter of dimension of the chisel brakepoint 59, but smaller than the outer diameter of the threads 40 of thefastener so that those threads can still bite into the materialsurrounding the hole and alter the feed rate of the fastener asdescribed herein.

When the fastener 10 begins to advance and continues to advance into thesecond work piece as shown in FIG. 9, the threads 40 of the fastenergenerally pull the remaining shaft 30 (if any) above the threads, andthe head 20 of the fastener into and/or through the pre-bored hole untilrotation ends and the fastener achieves a desired depth of installationin the work pieces. As shown in FIG. 10, the fastener can be advanced sothat the threads 40 are substantially located in the second work piece106, but not the first work piece 102. The shaft 30 and head 20 of thefastener 10, however, can remain in the first work piece as the fastener10 also continues to advance into the second work piece 106. As aresult, the head 20 and optionally the shaft 30 can pull down the firstwork piece 102 into further securing engagement with the second workpiece, and can further pull the second work surface 109 toward and intoengagement with the first work surface 107.

Generally, the aforementioned depth of installation corresponds to thefastener head 20 being at least partially located, if not fully locatedwithin the pre-bored hole 103. The head 20 also can be generallyconcealed from view for a viewer V from above. For example, the head canbe sufficiently buried in or located within the interior of thepre-bored holed in the first work piece so that it is not readilyvisible to a viewer V from above without close inspection. Sometimes,where the work piece is constructed from wood or composites, thematerial around the pre-bored hole may swell or at least partially fillthe pre-bored hole above the head back in to even further conceal thehead of the fastener 10.

The depth of the fastener 10 in the work pieces after installation alsocan correspond to a sufficient portion of the threads 40, and shaft 30if desired, being located within the second work piece, and a sufficientportion of the shaft, as well as the head 20, being located in the firstwork piece, where the fastener joins the first and second work pieces toone another.

A chart illustrating the feed rates as the screw 10 is advanced ispresented in FIG. 11. There, the y-axis represents the feed rate inmillimeters of advancement into the work piece per revolution. Thex-axis represents the passage of time as the fastener is installed,starting from when the fastener first engages the first work piece atT0, where time is equal to zero, to when the fastener is fully installedat TE. The theoretical feed rate TFR, also referred to as a first feedrate herein, is a function of the geometry of the thread, and moreparticularly, the pitch and/or angle of the threads as explained above.As shown in FIG. 11, during time T0, as the fastener is initiallyrotated, it begins to engage the work piece, so it does not feed intothe work piece.

As the fastener 10 continues to rotate and penetrate into the workpiece, the threads 40 engage the work piece. Generally, however, thethreads during time T2 do not substantially advance the fastener 10 intothe work piece. Much of the advancement, or the feed rate F2 in general,is due to the force being applied to the fastener through the head. Someor a small part of the advancement can be provided by the threads duringT2. During T2, the chisel brake point 59 can pre-bore the hole for theremainder of the fastener.

The fastener 10 can continue to be rotated and advanced at feed rate F2a preselected distance 77 (FIG. 8) into the work piece 102, withprogressively more of the threads 40 of the fastener 10 engaging thework piece until that engagement of the threads with the work piece atleast partially, if not substantially, overcomes the braking force. Atabout that point, the advancement of the fastener 10 can generallyincrease from the second feed rate F2 to a greater third feed rate F3,that is optionally between the second feed rate F2 and the first feedrate TFR. This increase in the feed rate is generally represented inFIG. 11 between the transition between F2 and F3. While the transitionbetween the feed rates is shown as abrupt, it can occur gradually ifdesired.

The fastener 10 can continue to advance until it extends through thefirst work piece and engages the second work piece. Shortly after itengages the second work piece, the rate of advancement of the fastenercan further increase, transitioning from the third feed rate F3 to thefourth feed rate F4. This increase can be due to many, if not all of thethreads 40 engaging the work piece(s) to advance the fastener into thework piece(s). The fastener 10 can continue to be advanced at the fourthfeed rate F4 that is optionally between the third feed rate and thefirst feed rate TFR, and optionally at or near the first feed rate orTFR.

In operating at the fourth feed rate F4, the fastener 10 can be advancedinto the first surface 107 of the second work piece 106 as shown in FIG.8. Generally, the fastener can be advanced into the second work piece,which can be an underlying work piece, such as a floor joist at a fasterfeed rate, such as the TFR because there is not much concern ofsplitting or damaging that structure as a result of the screw shaftbeing wedged or quickly advanced into the material of that work piece.Optionally, the fastener 10 can be advanced into the second work pieceparallel to the longitudinal length of the second work piece. When thefastener is fully installed in the work pieces, the advancement stops,which is represented at TE in FIG. 11.

Generally, the changes from one feed rate to another as mentioned abovecan occur due to the geometry and interaction of the chisel brake point,threads and head of the fastener with one another and/or the workpiece(s), rather than due to changes in the external forces F1, F2, F3,F4 or other forces applied to the fastener as it is advanced. Indeed,the forces F1, F2, F3 and F4 can be substantially the same throughoutthe advancement of the fastener into the work pieces. Likewise, the rateof revolutions per minute (RPMs) of the fastener can remain generallythe same throughout the advancement of the fastener in to the workpieces. What can change however, is how fast the fastener advances underthose RPMs, again, due to the geometry of the fastener and theinteraction of its components.

Although the different feed rates F2, F3 and F4 are shown astransitioning from one to the other rather abruptly, those feed ratescan transition from one to the other gradually, so that the transitionsare less stepped. This can be achieved by varying the geometry of thethreads, the chisel brake point, and or other features as desired.

I. First Alternative Fastener Embodiment

A first alternative embodiment of the fastener is illustrated in FIGS.12-17 and generally designated 110. This embodiment is similar to theabove embodiment above in construction and operation with a fewexceptions.

To begin, the end 150 of the fastener can include a different threadgeometry and inclined surface configuration. For example, the end 150can include a chisel edge 156 that extends across the diameter 132 (orsome other chord or dimension) of the shaft 130. The chisel edge 156 canbe in the form of and function like the chisel brake point explainedabove if desired. However, the chisel edge 156 also can extend slightlybeyond the outer diameter 132 of the shaft 130 as shown in FIGS. 15 and16 by a distance 137. In so doing, at least a portion of the last thread146, for example, the leading portion 148, can form part of the chiseledge 156, or more generally the chisel brake point. With the last thread146 forming this extension, the chisel edge 156 can be configuredasymmetrically about the longitudinal axis 200. For example, a firstportion of the chisel edge 156 can extend a first distance D1 from thelongitudinal axis on one side of the axis, and a second portion locatedon the opposite side of the longitudinal axis can extend a seconddistance D2 on the other side of the longitudinal axis 200. The distanceD1 generally can be greater than distance D2. This difference in thedistances can be equal to the depth of the last thread, or some otherdimension as desired.

The chisel edge 156 extends rearward from the very end of the fastener150 generally in a V-shape with the inclined surfaces 152 and 154inclined relative to one another at an angle μ which can be in the rangeof about 90° to about 105°, or optionally about 90° to about 135°, orfurther optionally about 90° to about 150°, or even further optionally90°±10°. It has been discovered that with these ranges of anglesincorporated into the chisel edge, the fastener 110 can pre-bore holeswell into composite work pieces, as well as fiber or natural wood workpieces. For example, this range of angles is blunt enough so that it canslow or retard advancement of the screw into a wood board, and allow ahole to be pre-bored therein. Substantially more acute angles, where μis less than 45°, on the other hand, can be too pointed, and can causethe fastener to rapidly drill into the wood board, almost at, if not at,the theoretical feed rate of the fastener and related threads. In turn,this rapid advancement of the fastener can split or damage the workpiece.

The above range of angles is also sharp enough so that the end of thefastener can pre-bore a hole, rather than melt a hole in a work piece,such as a board, that is constructed from composites, such as a polymeror plastic or wood/plastic hybrid. Substantially more obtuse angles,where μ is greater than 170°, on the other hand, can be too blunt, andcan cause the fastener end to simply melt a hole into the wood workpiece, at a feed rate that is unsatisfactory for practical use. Inaddition, the melting of the work piece material can rapidly gum up thethreads of the fastener, and prevent the melted material from evermaking it to the surface of the work piece. In turn, this can cause thesurrounding material to bulge and present aesthetic issues.

Returning to FIGS. 15-17, the inclined surfaces 152 and 154 canintersect at the chisel edge 156 and form at least portion of it. One ormore of the inclined surfaces can transition to or merge with the lastthread 146. More particularly, the last thread 146 can form at least apart of, and lie in the same plane or curvilinear surface as, one ormore of the inclined surfaces 154. Depending on the angle of theinclined surface 154 relative to the longitudinal axis 200 or the othersurface, more or less of the last thread 146 can form a part of thatsurface.

Optionally, the inclined surfaces 152 and 154 can be located between aboundary 116 on the shaft 130 and the chisel edge 156 as illustrated inFIGS. 12-14. The boundary 116 can mark the location at which one or bothof the inclined surfaces begin on the shaft 130 or within the end 150 ofthe fastener 110. Where included, the thread 140 and/or last thread 146also can be formed beyond the boundary 116, in the end, between theboundary and the chisel edge or chisel brake point. Optionally, thesethreads can also extend rearward from that location toward the head in acontinuous, generally uninterrupted manner as well.

As shown in FIGS. 15 and 16, the last thread 146 merges or transitionsinto the inclined surface 154 at the intersecting portion 147 of theseelements. This intersecting portion 147 can lie within the same plane orcurvilinear surface as the inclined surface 154, and can form acontinuous surface with the inclined surface 154 as illustrated. Theintersecting portion 147 can extend the inclined surface 154 beyond theshaft 130 a distance equal to the depth of the last thread 146, theleading portion 148, or some other distance. Thus, with thisintersecting portion acting as extension of the inclined surface, theinclined surface 154 can have a greater surface area than the opposinginclined surface 152. Optionally, although not shown, a part of the lastthread can extend beyond the chisel edge 156, in which case, that partcan form a portion, and optionally another surface extension of theother inclined surface 152 as well.

Returning to FIGS. 15-17, the last thread 146 can include a leadingportion 148 at which the last thread terminates. The leading portion 148can be the part of the last thread that actually merges or transitionsdirectly into the inclined surface(s), and can include at least aportion of or overlap the intersecting portion 147. The leading portion148 can extend all the way to the chisel edge 156, or it can extendsomewhat beyond the chisel edge and form part of the other inclinedsurface 152, or it can terminate somewhere adjacent the inclined surface154, and/or the inclined surface 52.

The leading portion 148 can extend outward from the shaft 130 the fulldepth of the other threads 140, or some other preselected greater orlesser depth. The leading portion can transition rearward from thechisel edge 156 to the remainder of the last thread 146, which in turnfurls or coils around the shaft 130 at or near the end 150, depending onthe thread configuration, and transitions to the other threads 140extending outward from the shaft. The leading portion 148, the lastthread 146 and the other threads 140 can form a unitary thread thatextends from the chisel edge 156 continuously up the shaft 130optionally without any interruptions or voids in the thread, until itterminates somewhere in a middle region of the shaft 130.

Optionally, the threads 140, 146 and fastener 110 in general can be voidof any self-tapping grooves or discontinuities that assist the fastenerinitially penetrating a very dense material, such as a metal. The upperand lower thread surfaces 141A and 141B of the last thread 146 and theremaining threads 140 likewise can be continuous from the chisel pointto the end of the threads 140 in the middle region of the fastener 110.Of course, if voids or interruptions are desired in the threads forcertain applications, they can be included.

Further optionally, the last thread 146 can merge with the inclinedsurface at the leading portion 148, with the last thread and all threadsterminating at that location. As an example, there may be no additionalthread or threads or portions of threads located between the chisel edgeand the leading portion.

As shown in FIG. 17, the leading portion 148 optionally also can includea forward surface 148A which generally is located adjacent and forms apart of the lower thread surface 141B. The forward surface 148A cangenerally be inclined or effect relative to the axis optionally by about0° to about 45°, further optionally about 2° to 10°. The forward surface148A optionally can extend all the way to and generally intersect thechisel edge 156. Opposite the inclined surface 154, in someapplications, the forward surface 148A can also form a partial extensionof the chisel edge 156. If desired, the forward surface 148A can form aramp from a location at or adjacent the chisel edge 156. This ramp canoperate to scrape material from the bottom of the hole 103. This rampalso can operate to scoop or route material 104 adjacent the shaft 130,can be onto the lower thread surface 141B. As the fastener turns, thescooped material augered farther up the lower thread surface 141B.

The fastener of this first alternative embodiment as shown in FIG. 12can be of a length 144, and generally divided into a first portion 142and second portion 143. Optionally, the length 144 can be about 1.5 toabout 2.0 inches, optionally about 1.8 inches, with the first portion142 being about half the length 144 and the second portion 143 beingabout half the length as well. Of course, the screw may be of variousother lengths, or example, it can be 2 inches, 3 inches, 4 inches orother increments therebetween depending on the application. Further, thefirst and second portions 142 and 143 can be subdivided in differentratios depending on the application.

The first portion 142 can include primary threads 140 and the chiseledge 156 described above. The first portion 142 can be about half thelength 144 of the fastener, or about ⅓ or ¼ the length of the screw, orother portions as desired. The second portion 143 can be threadless andcan include an optional head 120 of the fastener 110. The outsideprimary threads near the end 150 can be less sharp than the threadscloser to the head 120 of the screw if desired to prevent the or impairthose threads from biting into and advancing the fastener into the workpiece at an undesired rate. Of course, the threads can be uniformlysharp from end to end. The pitch of the threads 140 optionally can beabout 2 mm to about 4 mm, and further optionally about 3 mm. Generally,as used herein, the pitch refers to distance from one point on thethread to the corresponding point on an adjacent thread measuredparallel to the axis 200.

The threads 140 and the last thread 146 can be of a thread design havinga “V” profile or a buttress profile depending on the application.Further, as shown in FIG. 12, the threads and last thread can eachinclude a thread angle Ø, which is generally the included angle formedbetween the upper and lower thread surfaces 141A and 141B. This anglecan be optionally between 10° and 90°, further optionally between 30°and 70°, and still further optionally between 55° and 60°, and evenfurther optionally about 60°.

The threads 40 each can also include crests 111 and roots 112 betweeneach crest of the threads. As shown in FIGS. 12 and 16, the last threadcan include a crest 113. This crest 113 can continue to the leadingportion 148, or can terminate short of it as desired. The crest 113, andmore generally the last thread 146 also can thin substantially in theintersecting portion 147 where the last thread 146 merges or transitionsinto the inclined plane 156. Indeed, the inclined surface 154 andintersecting portion 147 can extend outward to the crest 113, such thatthe planar, curved or other surface of the inclined surface and/orintersecting portion terminates at the crest 113 for at least a portion,if not all of the last thread 146 and/or the leading portion 148.

As illustrated in FIG. 16, the inclined surface 154, and moreparticularly the intersecting portion 147, can form a part of the lastthread where the last thread merges into these elements. For example,the last thread in this region can generally include the lower threadsurface 141B on one side of the crest 113 of the last thread, and caninclude the intersecting portion 147 that merges with the inclinedsurface 154 on the opposite side of the crest 113 of the last thread146. As the last thread 146 furls or coils away from the leading portion148 or the chisel edge 156, the inclined surface 154 and/or intersectingportion 147 themselves can merge or transition to the upper threadsurface 141A in the transition region 115. This transition can beabrupt, with a perceivable drop off from the inclined surface 154 and/orintersecting portion 147 to the upper thread surface 141A, or it can begradual, with inclined surface 154 and/or intersecting portion 147angling or curving away from the upper thread surface 141A at a smallangle or curvature.

While the second portion 143 can be unthreaded, it optionally caninclude secondary threads 145 as shown. These secondary threads 145 canbe included on the shaft 130 at or near the head and can extend apredetermined distance within the second portion 143 of the length ofthe screw 110. The primary threads 140 and secondary threads 145 can beseparated by a void located along the shaft 130. the void can be of apreselected length 149.

The secondary threads 145 can be of the same threading as the primarythreads 140, or alternatively can include a reverse thread, generallyrunning in the opposite direction of the threads 140 in the firstportion 142. The pitch on the secondary threads 145 optionally can beabout 2 mm to about 4 mm, and further optionally about 3 mm. The pitchon the secondary threads 145 can be about 1.5 to 2 times greater thanthe pitch on the primary threads 340, in addition to being reversethreaded along the shaft 130. Further, the outer diameter D3 of thereverse threads 145 can include an outer diameter that is smaller thanthe outer diameter D4 of the primary threads 140. As an example, theouter diameter of the reverse threads can be about 1.4 inches, and theouter diameter of the primary threads can be about 1.6 inches.Optionally, the outer diameter of reverse threads 145 can be about 0.1to about 0.4 inches less than the outer diameter of the primary threads140.

The head 120 of the fastener shown in FIG. 12 optionally can be of adiameter D5 that is greater than the other diameters D3 and D4. Thislarger size of the head can enable a drive tool to be attached to thehead and driven. The larger size of the head can also enable the head toengage the material surrounding the pre-bored hole 103 and provide someholding force, in addition to the shaft, to hold the work pieces in adesired orientation.

In operation, the screw 110 can function and can be installed in amanner similar to the embodiments described above. Where the leadingportion 148 and last thread 146 terminate adjacent or near one or moreof the inclined surfaces, however, these features can provide enhancedaugering. For example, as shown in FIG. 17, as the material 104 isscraped from the work piece within the pre-bored hole 103, the smallpieces of material, which can be in the form of chips, fragments,fibers, or parts of the work piece are scraped from the bottom of thehole by the leading portion 148. In effect, these parts can be scoopedor picked up by the leading portion 148 and the last thread 146, andwhere included, the forward surface 148A, and augered up the last threadto the other threads 140. The material 104 can travel on the lowerthread surface 141B as illustrated, generally continuously up thethreads until it is ejected out from the hole to the environment or intoa tool as described below.

In applications where the work piece into which the fastener 110 isadvanced is a composite board, the scooping and scraping action of theleading portion and end 150 can almost immediately auger out thematerial 104 from the pre-bored hole. This can prevent melting of thatcomposite material due to excessive churning in the bottom of the hole,which in turn can prevent the screw from becoming gummed up with themelted material as it is augered up the threads, thereby impairingadvancement of the screw into the composite.

FIG. 18 illustrates the fastener 110 installed in work pieces 102 and106 at a predetermined angle, much like the embodiment described above.Leading up to that installation, the fastener 110 can undergo theoperations, can be installed at the angles, and can feed at the feedrates as described in any of the embodiments above to connect the workpieces 102 and 106.

As shown in FIG. 18, however, the optional additional secondary threads145 can provide a slightly different holding effect than that of theembodiments described above. For example, where the secondary threads145, which again may be reverse threads, are included, those reversethreads can assist in drawing the work piece 102 more toward the secondwork piece 106. Further because there is a void between the primarythreads and the secondary threads, that void can allow the first workpiece 102 to draw down against the second work piece 106. The optionalreverse threads also can rotate within the pre-bored hole 103, therebyscraping the loose ends of material from that hole, which can provide aclean finished hole above the location where the head 120 comes to restafter being fully installed.

After the fastener 110 is fully installed, the optional reverse threadscan provide additional holding power to prevent the work piece 102 frombeing removed from the second work piece 106 under force. For example,the added contact between the reverse threads and the materialsurrounding the pre-bored hole 103 can provide more friction between thefastener and the hole, which in turn can make much more force requiredto pull the work piece 102 away from work piece 106.

Optionally, a first fastener 110 is installed on one side of a workpiece 102, such as a board, and a second fastener is installed directlyacross from the first fastener on an opposite side of the board, and insome cases in the same plane as the first fastener. Where these opposingfasteners optionally include the secondary threads, these threads canprovide even more holding force to keep the work pieces fastenedtogether.

II. Second Alternative Fastener Embodiment

A second alternative embodiment of the fastener is illustrated in FIG.19 and generally designated 210. This embodiment is similar to the aboveembodiments in construction and operation with a few exceptions. Forexample, the end 250 of the screw 210 can generally include a lastthread 246 that is included within the primary threads 240. This lastthread 246 can also include upper 241A and lower 241B thread surfaces,as can the remainder of the primary thread 240 as illustrated in FIG.19. The last thread 246 can end at a leading portion 248. This leadingportion 248, and more generally the last thread 246, can transition ormerge with the inclined surface 254. This merging or transition canoccur at the intersecting portion 247. This intersecting portion canform a continuation or extension of the surface of the inclined surface254. The last thread 246 can also transition at the transition region215 into the inclined surface 254. As can be seen in FIG. 19, theleading portion 248 is adjacent the chisel edge 256, but does not form adirect extension of that chisel edge 256. The surface area of theinclined surface 256 thereby can be increased by the area correspondingto the intersecting portion 247.

The operation of the second alternative embodiment in FIG. 19 is similarto that of the embodiment in FIGS. 12-18. For example, the leading edge248 and/or last thread 246 acts to scoop up material and transfer it tothe surfaces of the threads so that that material can be augured up andout of a pre-bored hole created by the chisel edge 256. Moreover, thechisel edge 256 and respective components can operate like a chiselbreak point as described in the embodiments above. In somecircumstances, however, the scooping action by the leading portion 248can be slightly less than that of the embodiments described above due tothe leading portion 248 not being disposed at the point of contact withthe bottom of the pre-bored hole or the material, that is, directlyadjacent the end forming an extension of the chisel edge 256.Optionally, if desired, the leading portion 248 can be moved to thelower most extremity of either of the inclined surfaces 252, 254. Thechisel edge of this fastener surface can also include a chisel brakepoint as described above.

III. Third Alternative Fastener Embodiment

A third alternative embodiment of the screw is illustrated in FIGS. 20and 21 generally designated 310. This embodiment is similar to the aboveembodiments in construction and operation with a few exceptions. Forexample, the chisel edge 356 includes a small apex or point 357 at whichthe chisel edge sub portions 356A and 356B intersect. In this chiseledge construction, the chisel edge sub portions can be at an angle Arelative to one another. This angle can generally be an obtuse angle,that is, greater than 90° and optionally less than 180°. In thisembodiment, the inclined surfaces can be divided into sub portions 352 aand 352 b, and 354 a and 352 b, or additional sub portions if desired.These sub portions can include the negative rake angles or other anglesof the inclined surfaces of the embodiments described above. The screwof this embodiment also can include a last thread 346 with a leadingportion 348 that merges or transitions into one or more of the inclinedsurfaces, generally forming an extension of those surfaces, the chiseledge, or other components of the end of the screw. Further, the chiseledge of this fastener can include a chisel brake point and can operatelike the embodiments described above.

IV. Installation Tools

As mentioned above, a tool can be used to start and advance the abovementioned fasteners, or other fasteners, into one or more work pieces tojoin those work pieces in the manners explained above. For example, atool can be used to start a screw and subsequently advance the screwthrough the side of a board and subsequently into an underlying oradjacent joist or other structure.

A current embodiment of a tool suitable for such a fastener installationis illustrated in FIGS. 22-24, and generally designated 60. As shownthere, the tool 60 can include a frame 62 including a handle 61, a guide80 and an optional clamping assembly 77. The frame 62 can include abottom surface 69 that is adapted to engage a top surface 1011 of a workpiece 102. This work piece can be a board or any other type of structuredescribed herein. The tool can be used to install a fastener 110 asdescribed above through the first work piece 102 and into the secondwork piece 106.

Generally in the embodiments shown, the work piece 102 can include afirst surface, also referred to as a side surface 108 that lays in afirst plane 1013. Opposite the first surface or side surface 108, on theopposite side of the work piece, can be an opposing side surface 115, orfourth surface, that lays generally in a fourth plane 1016. The workpiece 102 also can include a third surface or top surface 1011 thatgenerally lies at least partially within a third plane 1012, and asecond surface or bottom surface 109 that generally lies in a secondplane 1014 that is parallel to and on the opposite side of the workpiece from the top surface 1012. The first surface 108 and fourthsurface 115 can be generally perpendicular to the top 1011 and bottom109 surfaces of the work piece 102.

The guide 80 of the tool 60 can generally define an angled bore 84 thatis positioned in a non-orthogonal angle, or generally angularly offsetfrom 90°, relative to the side surface 108 of the first work piece 102when the tool 60 readied for advancing the fastener. The angled bore canextend from a first opening 84 to a second opening 85. The first openingcan be configured to receive a fastener and generally operate as anentrance into which a fastener can be inserted into the tool 60. Thesecond opening 85 can serve as an exit through which the fastener exitsthe tool 60 as it advances into the work piece 102.

The angled bore 88 in this embodiment, and in particular the guide 80,can include first and second guide plates 81 and 82. These guide plates81 and 82 can be constructed from stamped parts forming opposing halvesof the angled bore. The stamped parts can be metal, such as steel,stainless steel or other metals, or optionally composites or polymers.The stamped metal halves cooperate to form the angled bore 88.

As shown in FIG. 23, the guide plates 81 and 82 can include opposingtabs 86 and 87 (FIG. 23) that extend radially outwardly generally fromthe angled bore and/or the axis 400 of the angled bore. These tabs 86and 87 can be positioned in the frame 62 so that they engage and contactone another. To join the tabs 86 and 87, the tabs can be inserted inslots 64 defined by certain portions of the frame 62. When placed in theslots, the guide plate tabs 86 and 87 can be held in close proximity toone another to generally secure the opposing halves 81 and 82 of theguide 80 together. Of course, where other constructions are desired, theguide plates 81 and 82 can be of a unitary construction such that thetabs 86 and 87 are eliminated. For example, in the embodiments describedbelow, the angled bore 84 can simply be defined by a unitary structurescrew guide. Alternatively, the plates 81 and 82 can be joined withfasteners projecting through or otherwise fastening the tabs 86 and 87.

Optionally, a protective plate 92 can be included with the tool 60. Thisprotective plate 92 can be placed adjacent the first opening 84 togenerally protect the uppermost edges of the guide plates 81, 81 fromdamage when the fastener 110 or a portion of a tool 101 is inserted inthe angled bore 88. For example, the protective plate 92 can define aplate bore 94, which can be generally aligned with and/or centered onthe axis 400 of the bore 88. The inner edge of the protective plate 92adjacent the plate bore 94 can extend over and at least partially orfully cover the edges 98 of the respective guide plates 81 and 82. Withthe inner edge of the protective plate covering the edges of the guideplates, a fastener 110 or portion of the tool 101 can be guided orgenerally deflected so it does not engage those edges 98. In turn, thiscan prevent chipping, marring, breaking or other damage to those edges98 and more generally to the guide plates with the fastener or tool. Ofcourse, if desired, the guide plates themselves can include integralprotective plates extending therefrom, or the protective plate 92 andsimilar devices can be absent from the construction altogether.

The frame 62 and the other various components of the tool 60 can beconstructed from stainless steel, steel, other metals, composites and/orpolymers. For example, as mentioned above, the guide plates 81 and 82,as well as the optional protective plate 92 can be constructed fromsteel, while the like components of the frame 62, such as the handle 61,the secondary handle 64 and the spacers 74 and 79 can be constructedfrom a polymeric material such as a high impact resistant plastic.

Referring to FIGS. 22 and 23, the guide 80 and/or frame 62 can include aspacer 74 that extends downwardly from the bottom 69 of the frame 62.The spacer 74 includes opposing side surfaces 78A and 78B. The sidesurface 78A can be configured to engage and rest immediately adjacent orup against the side surface 108 of the work piece 102. The opposing sidesurface 78B of the spacer 74 can be configured to be positioned adjacentanother work piece 119 positioned near the first work piece 102, asdescribed below.

The spacer 74 can project downwardly or generally protrude into a space105 that is immediately adjacent the side surface 108 of the work piece102. This space 105 can be defined by the dimension or width of thespacer 74 between the side surface 78A and the second side surface 78B.Of course, if other types of spacers or indexing elements are desired,they can be included and extend outwardly from the bottom surface 69 ofthe frame 62. For example, the spacer 74 can be configured to fit in thespace 105 that is immediately adjacent the side surface 108 of the workpiece 102 as shown. The spacer can be of a dimension or width, forexample about ⅛ to ½, or about ¼ of an inch, to effectively set thepreselected spacing or distance between a first work piece 102 and athird work piece 119 as shown in FIG. 22. Alternatively, the spacer canbe dimensioned to precisely fit between already preinstalled work piecesor boards to further fasten those boards to underlying substructures orimprove the fastening of the boards to other structures.

The side surface 78A of the spacer 74 also defines the second opening 85of the angled bore 84 through which a fastener is adapted to exit.Further, the guide plates 81 and 82 can extend downwardly to the opening85 and terminate at or adjacent the side surface 78A. The second opening85 can be positioned a preselected distance away from the bottom surfaceof the frame 62 in certain applications. Although as shown the secondopening 85 opens out the side surface 78A of the spacer 74, the angledbore alternatively can be constructed so that it opens out the bottomsurface 69 of the frame 62 (not shown).

With the illustrated configuration of the guide 80 and the spacer 74,the angled bore 84 extends through these elements and generally throughthe space 105 immediately adjacent the side surface 108 of the workpiece 102. The angled bore 88 can substantially encase or otherwisecontain a fastener 110 all the way up to the side surface 108 of thework piece 102. Optionally, the opening 85 can be placed within about1/16 to about ⅛, further optionally about 1/16 to about ¼ of an inchfrom the side surface of the work piece 102. Further optionally, theopening 85 can be configured so that at least a portion of it layswithin a plane that is generally parallel to the plane 1013 in which theside surface 108 of the board lays.

Accordingly, when the fastener 110 is rotated, even when its endincludes a chisel break point or other construction, that end isrestrained and generally contained in the bore 88, so that it does notwobble excessively, even when beginning to penetrate the side surface108 at the angle as illustrated or described in the embodiments of thefastener above. This can provide a precise alignment of the fastener 110into the side surface of the work piece 102 and into or through othersurfaces of that work piece 102 and underlying work pieces 106.

The fastener guide 80 can also be configured to include a materialejection port 83 that is in communication with the angled bore 88. Asshown in FIG. 24, the guide plate 81 can define a material ejection port83. The material ejection port 83 can be a hole that is located betweenthe first opening 84 and the second opening 85. The precise location ofthe material ejection port 83 and its dimension can be selected based onthe material to be augured or otherwise ejected or evacuated out fromthe angled bore 88. As illustrated, the material ejection port ispositioned generally above the bottom surface 69 of the frame 62, andcan be about ½″ long. Of course, it can be of other dimensions, forexample about ⅛ to about ¼ of an inch in length. Generally, it can be ofa dimension that is sufficient to allow material augured by a fastener110 to eject from the port 83.

The material ejection port 83 can be dimensioned and located so that itis defined on the underside of the angled bore 88 so that the materialdrops out from the bore via gravity through the port. The materialejection port 83 can be large enough to drop out fibers or othermaterial augured from the work pieces, yet small or short enough so thata screw inserted into the angled bore 88 from the first opening 84 willnot have its end drop out from, or otherwise protrude, or get hung up inthe ejection port 83 while the screw moves toward the second opening 85.

The material ejection port 83 can include a lowermost rim 95 as shown inFIGS. 23 and 24. This lowermost rim can be positioned so that it islocated above the top surface 1011 of the work piece 102, and/or so thatit is also located above the top surface 1111 of an adjacent work piece119. With such a positioning of the lowermost rim of the materialejection port, material augered up through the angled bore can beejected out from the bore generally above the top surface 1011, as wellas the top surface 1111 if the work piece 119 is in place adjacent thework piece 102. In turn, the ejected material can freely flow out fromthe port over or adjacent the lowermost rim 95. It is noted that thelowermost rim may be considered to be above the top surface 1011 of aparticular work piece merely because it is above the plane in which thesurface is located. For example, the lowermost rim 95 in FIG. 24 can beconsidered above the top surface 1011 even though it is not directlyover that top surface 1011. Optionally, in certain applications, thematerial ejection port can be eliminated from the tool.

The material ejection port also can be housed between opposing frameflanges 75 which extend from the rearward portion of the frame 62. Theseflanges 75 can extend outward a sufficient distance to generally concealthe material ejection port 83. If desired, the flanges can form andinclude a pivot axis 73. The frame itself 62 can pivot about this pivotaxis 73 in the direction of the arrow 75A after a fastener has beensufficiently advanced and installed in a work piece 102 to fasten orjoin it with another work piece 106. By pivoting the frame about thepivot axis 73 and in general having the frame rotate on the rearwardportion of the flanges 75, undue stress and forces on the spacer 74 canbe reduced or eliminated. This can add to the longevity of the spacer,particularly where it is constructed from a polymer material. Of course,the flanges 75 can be eliminated altogether if desired.

With further reference to FIG. 23, the material ejection port caninclude edges 89 constructed to function as wipers to wipe or pullmaterial 104 entrapped within the threads 140 of the fastener 110 outtherefrom. The edges can be configured to extend generally along orparallel to the axis 400 of the angled bore. Of course, the edgesalternatively can be offset at a predetermined angle relative to thataxis 400 as desired. The edges can be somewhat sharpened or otherwisedisposed at a right angle relative to the rotation of the fastener 110.In this manner, any excessive material that protrudes from beyond thecrests of the fastener threads can catch or otherwise engage the edges89. In so doing, the edges can dislodge the material 104 from thethreads and cause it to further drop out with the assistance of gravityfrom the port 83. Where the material 104 is taken from a work piececonstructed from a composite or polymer or an extremely fibrousmaterial, the wiper edges can act to wipe these materials from thefastener as it rotates the angled bore 88 to prevent or impair bindingof the fastener 110.

Generally, the wiper edges can be generally linear, but of course can betapered or curved as desired. Further, the edges can be positionedsomewhere around the circumference of the fastener 110 so that as thefastener rotates at least a portion of it passes by and is capable ofengaging augered material associated with the fastener against theedges. In some circumstances, where the material is known not to be of atype that would excessively bind the rotation of the fastener 110, theedges can be absent. For example, the material ejection port can extendall the way around the circumference of the angled bore 88.

The material ejection port can serve to remove or eject bored materialfrom the angled bore to reduce some or all of the amount of materialpulled back into the pre-bored hole by the fastener, which in some casescan cause damage, such as splitting or bulging of the work piece in thearea surrounding the fastener. For example, the material ejection portcan enable material augered up from the work piece to be ejected awayfrom the threads and shaft of the fastener. In cases where the materialejection port is absent, or otherwise does not facilitate ejection ofthe material from the bore, and the head of the fastener is dimensionedso that it is almost the same dimension as the angled bore, the headmight capture and drag all the pre-bored material back into the hole asthe head advances toward the hole. That material would be captured inthe space between the shaft and threads, and the walls of the angledbore, with the head acting like a cap or piston to pull the augeredmaterial between it and the work piece back into the pre-bored hole.With the material ejection port, the material augered or removed fromthe hole is ejected from the bore so that there is minimal, if any,augered or removed material for the head to pull into the hole. In turn,this can reduce the likelihood of damage to the work piece around thearea of the hole caused by the material entering the hole, possiblyalong with the components of the fastener. Of course, in certainapplications where material might not readily be pulled into the hole bythe fastener, the material ejection port can be eliminated.

As shown in FIG. 24, the guide 80 optionally can include a beveledportion 83A adjacent the lower extremity of the port 83. This beveledportion can generally increase the internal area of the bore adjacentthe port 83. The bore also can serve as a ramp to assist the material104 being ejected out from the bore 88 through the port 83. The angledbore 88 can have an internal dimension D7, which can be in the form of adiameter about 0.1 to about 0.4 inches, optionally about 0.15 to about0.75 inches, or other dimensions greater or less as desired. In general,the diameter D7 can be slightly larger than the dimension than the headD5 of the fastener 110. For example, the dimension of the diameter D5can be about 0.001 to about 0.05 inches less than the diameter D7 of theangled bore 88. Other tolerances can be suitable as well, depending onthe application. The diameters D5 and D7 can be matched so that the headof the fastener does not excessively wobble or move other thanrotationally and/or along the axis 400 of the angled bore 88. This inturn can reduce, impair or otherwise prevent wobble of the fastener 110as it is advanced into the work pieces. It also can prevent or impairthe axis of rotation 200 of the fastener 110 from becoming misaligned orsubstantially non-parallel with the axis 400 of the angled bore 88,which also can be considered the advancement axis of the fastener 110.In certain circumstances where the axis 200 of the fastener 110 becomessignificantly deviates or is at a substantial angle relative to the axisof advancement 400 of the angled bore 88, it is possible that theportions of the fastener can bind against the material surrounding thesecond opening. In limited circumstances, this can impair advancementand/or rotation of the fastener and/or otherwise impair the functioningof the tool and its removal from the respective work piece.

The angled bore 88 as shown in FIGS. 22 and 24 can be configured so thatit is of a length that closely corresponds to the length of the fastener110. For example, the length of the angled bore 88 can be about 1.9 toabout 2 inches in length, while the length of the screw is about 1.5 toabout 1.9 inches in length. Of course, other lengths of the bore andfastener could be selected and still function suitably for otherapplications. With this particular embodiment, where the fastener isslightly shorter than the length of the angled bore 88, the fastener 110can be substantially encased within the angled bore 88 immediatelybefore it is advanced into the work piece. In this manner, the featuresof the fastener can be restrained or otherwise contained within the boreto prevent excessive wobble. For example, the end of the fastener can beclosely constrained as it begins to penetrate the side surface 108 ofthe work piece 102.

Optionally, the angled bore can be about 0.01 to about 1.0 inches,further optionally about 0.25 inches longer than the fastener 110.Accordingly as shown in FIG. 24, when the fastener is positioned in theangled bore 88 before it is advanced into the work piece, as shown inbroken lines in FIG. 24, the head of the fastener 110 can be apreselected distance 72 inward from the portion of the frame 71surrounding the angled bore 88 and in particular the opening 84.Optionally, the angled bore 88 itself, in particular the guide plates 81and 82 can include a slight frustoconical taper at or adjacent the firstopening 84 extending outwardly to the surrounding portion 71 of theframe 62. With the head of the fastener 110 slightly disposed inwardlyslightly from the surrounding surface, a user can quickly center adrive, such as a Philips or star drive feature associated with a drill,in the head of the fastener. The region of the angled bore 88 above thehead of the fastener 110 can act to capture and guide the drive featureinto the head more easily. Alternatively, if desired, the fastener 110and angled bore 88 can be more grossly mismatched in length. Forexample, the fastener 110 can be longer than the angled bore 88 so thatit protrudes outward beyond the surrounding portion 71 of the frame 62 apreselected distance in certain applications.

With reference to FIGS. 22-23, the tool 60 can also include a clampassembly 77. This clamp assembly can include the first spacer 74 and asecond spacer 79 spaced distal from the first spacer. The distancebetween the first and second spacers can be about the width or slightlylarger than the width of the work piece into which the tool is designedto install fasteners. Further, this distance can be varied by operatingthe clamping assembly 77. For example, the second spacer 79 can bespaced about 5″-6″ from the first spacer 74 and can be actuated to movecloser to the first spacer 74 to close the distance between thoseelements to the precise dimension or width of the work piece 111 intowhich the fastener is to be driven. This can provide a clamping actionto clamp the side surfaces 108 and 115 of the work piece 102 betweenthese features of the tool. In turn, this can temporarily rigidly holdthe guide 80 and/or spacer 74 in a fixed orientation relative to theboard 102 and more particularly hold the axis 400 of the bore 88 in adesired alignment with the side surface 108 of the work piece 102. Inturn, the fastener can be rotated and advanced precisely into a desiredlocation through the side surface 108 and into and through the firstwork piece and/or second work piece. More generally, the clamp assembly77 can hold the tool 60 in a desired orientation and aim the fastener110 precisely into and/or through the work pieces.

Optionally, the clamp assembly 77, or more generally the tool when noclamp assembly is included, positions the first spacer side surface 87Aimmediately adjacent the side surface 108 of the work piece. The secondopening 85 can also be placed immediately adjacent the side surface 108of the work piece. In such a configuration, there may be little or nogap or void between the side surface and these elements. Accordingly,when a screw, for example, an embodiments of the fasteners describedherein, is rotated in the angled bore, it is rotationally constrainedright up to the side surface into which it is to advance. Where the endof the screw is configured to pre-bore a hole, this rotationalconstraint can offset the tendency of the screw end to wander or wobblewhen it is rotated against the work piece, and in turn assist instarting the screw in the work piece.

The clamp assembly further includes an arm 68, a secondary handle 64 anda biasing element 66, as shown in FIGS. 22 and 23. These elements canall be joined with a common element 63. The common element 63 can berotatably mounted on a pivot axle 65. The arm 68 can extend downwardlythrough a portion of the frame 62 and be connected with the spacer 79.The secondary handle 64 can extend at another location outward from thecommon element 63 and can be disposed generally adjacent the handle 61.The secondary handle 64 can be moveable relative to the handle 61 andgenerally relative to the frame 62. The secondary handle 64 can beconsidered movably joined with a frame 62 and adapted to actuate theclamp assembly and move the second spacer 79 to effectuate a clampingaction on the work piece 102.

Optionally, the secondary handle 64 can be spaced a preselected distancefrom the handle 61 so that a user can manually grasp simultaneously boththe handle and the secondary handle and squeeze those elements so thatthey move closer to one another. In so doing, the secondary handle 64rotates the common element 63 about the pivot axis, which in turnrotates the arm 68 and correspondingly the second spacer 79 toward thefirst spacer 74 to provide a clamping action on the work piece 102.

The secondary handle 64, as well as the arm 68 and spacer 79 can bebiased toward the configuration shown in broken lines in FIG. 22 by thebiasing element 66. This biasing element can be in the form of a biasingarm 66 that, when installed in the frame, can engage the interiorsurface 67 of the frame 62 and accordingly urge the common element 63 inthe direction of the arrow 63A shown in FIG. 22. In turn, this can urgethe secondary handle 64 and the arm 68 to the configuration shown inbroken lines in FIG. 22 as well.

To overcome this biasing action, a user can manually grasp a secondaryhandle 64 and pull it toward the handle 61, which will cause a clampingaction on the side surfaces 108 and 115 of the work piece 102, therebyholding the angled bore 88 and generally the axis 400 of the bore in adesired orientation relative to the side surface 108 of the work piece102.

Other biasing elements can be used to provide the clamping action of thetool 60 on the work piece 102. For example, instead of the biasingelement 66 being preformed and engaged against the interior of theframe, a coil spring or leaf spring could be positioned adjacent thecommon element 63 to urge the arm 68 and second spacer 79 in a desireddirection about the pivot 65. Optionally, the pivot could have a coilspring built between it and the common element to provide a biasingforce. Further optionally, the biasing element 66 could urge the arm andthe spacer in a direction about the pivot axis 65 in the directionopposite that shown by the arrow 63A in FIG. 22. In such a construction,the user would then move the secondary handle 64 away from the handle 61to open up the distance between the first spacer 74 and the secondspacer 79. With such an alternative configuration, upon installing therespective spacer on the opposing side surfaces of the work piece 102,the user could release the handle so that the biasing element urges therespective spacers to move relative to one another and provide aclamping action on the work piece 102.

With reference to FIG. 23, the second spacer 79 can define a recess orhole 76 therein. This recess can extend all the way through, or onlypartially through, the second spacer 79. This recess 76 can beconfigured to straddle or otherwise extend around a hole in whichanother fastener 110 is positioned. This can be helpful in cases wherethe area surrounding the hole 103 is slightly raised due to the boringof the hole 103 by the fastener, or where the fastener is not of thetype that pre-bores a hole, or where the fastener excessively bulges outmaterial in the area surrounding the fastener 110. The recess 76generally surrounds the area so that the bulge in the material does notaffect the dimension of the space 117 between the adjacent side surfacesof the respective work pieces 102 and 118. Accordingly, the spacer 79,even when overlapping bulged out material surrounding previouslyinstalled fasteners can be consistently spaced to provide a clean, evenappearance in the spacing between the adjacent work pieces. Althoughshown in a generally U-shape, the recess or hole 76 can be of square,rectangular, triangular, or some other geometric shape sufficient tosurround a fastener hole or fastener head on an adjacent work piece.Further, the recess 76 can extend farther up the arm 68 depending on theapplication.

Referring to FIGS. 22-24, a method for installing a fastener with thetool 60 to join work pieces will be briefly described. To begin, a firstwork piece 102 is provided where the first work piece includes a topsurface 111 and opposing bottom surface 109, a first side surface 108and an opposing side surface 115. The bottom surface 109 of the workpiece is placed adjacent the upper surface 107 of the second work piece106. As illustrated, the second work piece 106 can be, for example, aunderlying joist or subfloor. The first work piece 102 can be a deckboard or other board constructed from any suitable board material asdescribed above.

If a previous work piece 118 is already fastened to the underlying workpiece 106, the spacer tool 60 can be placed atop the work piece 102 withthe bottom surface 69 resting adjacent that the upper surface 1011 ofthat work piece 102. The spacer 79 can establish a preselected spacingthat is the equivalent of the dimension or width of the second spacer 79between the work piece 118 and work piece 102 and in particular the sidesurfaces of those work pieces that are adjacent one another.

The tool can be positioned so that the first spacer 74, and inparticular the first side surface 78A of the first spacer 74 ispositioned adjacent the side surface 108 of the work piece 102. In sodoing, the second opening 85 also is positioned adjacent that sidesurface 108, with the angled bore 88 and related advancement axis 400aligned at a predetermined non-orthogonal angle relative to the sidesurface 108 and the plane in which the side surface 108 lays. The secondopening 85 is located so that it is immediately adjacent the first sidesurface 108 of the work piece 102. To further secure and hold the angledbore 88 and opening 85 in these respective locations, a user canmanually grasp the secondary handle 64. In so doing, the handle actuatesthe common element 63 rotating it about the pivot axis 65. This rotatesthe arm 68 and accordingly moves the second spacer 79 toward the firstspacer 74. In turn, this can provide a clamping action to clamp thefirst work piece 102 between the first spacer 74 and the second spacer79. As an example, the first spacer 74 can engage the first side surface108, and the second spacer 79 can engage the other side surface 115.

A fastener 110 can be installed in the angled bore 88. Assuming thefastener is an equal or lesser length than the angled bore, the fastenercan bottom out and engage the side surface 108 of the work piece 102. Asmall distance 72 as shown in FIG. 24 will be left above the head of thescrew. A user can then advance a driving tool 101 toward the frame. Dueto the recessed configuration of the fastener head in the angled bore88, the tool can center within the angled bore 88 and come to rest inthe drive feature of the fastener 110.

While holding the tool 60 in a clamped configuration, with the axis 400along a desired line of advancement into the work piece 102, a user canactuate the drive tool 101 to rotate the fastener 110 as described withthe fastener embodiments described above, or some other fastener asdesired. The fastener 40 can be advanced along the axis 400 within theangle bore 88 so the fastener enters the first side surface 108 of thework piece 102 immediately after exiting the second opening 85 of theangled bore. The fastener then travels partially out the bottom surface109 of the work piece 102. Thereafter the fastener continues to rotateand penetrates the upper surface 107 of the second work piece 106 andcontinues to advance until the head of the fastener is at a desiredlocation, which can be within a pre-bored hole created by the fastener,or generally so that the head of the fastener is at least partiallyconcealed from view from above and generally does not obstruct thepositioning of another work piece adjacent the first work piece 102.

Where the fastener of the embodiments described above is used, as thefastener is advanced into the work piece 102, it pre-bores a hole, andthe material 104 from that hole is augured or otherwise fed up thethreads. The material is ejected or evacuated generally from the angledbore 88 through the material ejection port 83. This action is shown inFIGS. 23 and 24. Where the material ejection port 83 includes an edge 85adjacent the material ejection port 83, that edge can scrape auguredmaterial off from the threads or the remainder of the fastener 110, andassist in evacuating that scraped material from the angled bore 88.

After the first work piece 102 is installed and joined with the secondwork piece 106 with the fastener 110, a third work piece 119 (FIG. 22)can be installed adjacent the first work piece 102, atop the second workpiece 106. The tool can be moved to a position atop the third work piece119 in a manner such as that used in connection with the first workpiece 102. The first 74 or second 79 spacer, depending on theorientation of the tool 60, can establish the desired spacing betweenthe first work piece 102 and the third work piece 119. A new fastenercan be inserted in the angled bore as with the previous fastenerdescribed above. That new fastener can be advanced along the advancementaxis 400 in a manner described above to install the new fastener in thethird work piece 119 and second work piece 106 to join those work piecestogether. The above process can be repeated at worksite to installmultiple work pieces and join them with other work pieces.

Optionally, the tool 60 can be used to install multiple deck boards onunderlying substructure subfloor or joists. The work pieces can beboards, which as used herein can include deck boards, porch boards orother boards constructed from wood, particle board, composites,polymers, plastics, metal or other materials as desired. In installingthe fasteners and work pieces to join them together, the tool canprovide a way to quickly and precisely align the fasteners with therespective side surfaces of the work pieces or boards and install themin a manner such that they are generally concealed from view when viewedfrom a viewer directly above. Further, the angled bore, and inparticular the guide surrounding the angled bore extending upwardlyabove the upper surface of an adjacent work piece, can effectivelyprevent the threads of an advancing fastener from gouging, damaging ormarring an immediately adjacent work piece as that advancing fastener isadvanced into an adjacent work piece.

V. First Alternative Tool Embodiment

A first alternative embodiment of the installation tool is shown inFIGS. 25 and 26 and generally designated 160. This embodiment of thetool is similar to the first tool embodiment described above withseveral exceptions. For example, the tool 160 generally includes ahandle 161, a fastener guide 180, also referred to as a pilot element,and a spacer plate 174. The screw guide 80 can be installed in a frame162 constructed from a polymeric or other material, which can generallybe of a solid or hollow construction like that described in theembodiment above. The guide 180 can include an angled bore whichincludes first and second angled bore portions 188A and 188B. The firstportion 188A can be defined by the primary guide element 172 and thesecond portion 188B can be defined by the spacer plate 174, which alsocan be referred to as a spacer. The primary guide element 172 can beconfigured at an angle relative to the spacer 174, however, the angledbore portions 188A and 188B can be aligned with and parallel to oneanother along the axis 400 of the angled bore. As with the embodimentabove, this axis 400 can be configured and oriented at a fixedpredetermined angle relative the side of the work piece 102 into whichit advances a fastener 110. As with the above embodiment, a fastener 110can be disposed within and generally circumferentiated by the primary188A and secondary 188B portions of the angled bore 188. The primary andsecondary portions can be dimensioned to be the same, and slightlylarger than the outermost dimensions of the head and/or threads of thescrew 110, so that as with the embodiment above, the screw can beconstrained yet still rotate and advance along the axis 400 when drivenand rotated by a powered or manual tool.

The primary and secondary portions 188A and 188B of the angle bore canbe separated from one another by a gap 183 formed therebetween. This gapcan also be referred to as a material ejection port and can operatesimilar to the material ejection port described in the embodimentsabove. For example, material 104 that is scraped or pre-bored from awork piece 102 and augered up the angled bore can be ejected orextracted out the port 183 to prevent or impair binding of the fasteneras it advances or rotates.

Although the material ejection port 183 is shown as being formed byseparate elements, for example being formed between the spacer 174 andthe primary guide portion 172, the gap can be replaced with analternative structure. For example, the guide 180 and in particular theangled bore can extend all the way to the location adjacent the surfaceof the side surface 108 of the work piece 102. In this alternativeconstruction, the guide 180 can include a transversely drilled hole or amilled gap at least partially therethrough to allow the removed material104 to escape from the angled bore 188 as shown in FIG. 26. Optionally,the end of the guide 180 adjacent the work piece 102 can be at an anglethat corresponds to the surface of the work piece. Alternatively, theend of the guide element can terminate at a plane that is orthogonal tothe axis 400.

As shown in FIGS. 25 and 26, the spacer 174 can be in the form of aplate that is rigidly attached to the frame 162 with screws or otherfasteners so that it does not move laterally or vertically relative tothe remainder of the guide element 180 and/or the work piece as thefastener 110 is advanced through the tool 160. Accordingly, the featuresof the tool steadily aims the fastener toward a desired location on theside of the work piece 102, and constrains it, regardless of wobblingforces that are generated by the fastener engaging the work piece 102,as with the embodiments above.

As illustrated in FIG. 25, the tool 160 also can include a second spacer179. This spacer 179 can be mounted to an arm 177 that is further joinedwith a frame 162. The spacer can establish a gap between adjacent workpieces, much like that of the spacer in the first tool embodimentdescribed above. The arm 177 and spacer 179 can project through a slot178 that is defined in a portion of a frame 162. The spacer 179 canextend beyond the bottom surface 169 of the tool into a correspondingspace between adjacent work pieces. The spacer 179 optionally can beadjustable, moving within the slot 178 to accommodate work pieces ofdifferent widths. For example, the spacer 179 can move toward or awayfrom the first spacer 174 on the opposite end of the tool 160. With thisconstruction, the spacer 179 can set a gap between the first work piece102 being fastened down by the tool and a second work piece immediatelyadjacent that work piece. Optionally, the arm can be tensioned or underforce so that it is urged against the opposing side surface of the workpiece 102. In such a manner, it can act like a clamp to generally clampthe work piece between the first spacer 174 and the second spacer 179.The clamping action, however, can be somewhat less than that of theother tool embodiments described herein.

VI. Second Alternative Tool Embodiment

A second alternative embodiment of the fastener installation tool isillustrated in FIGS. 27-30 and generally designated 460. Theinstallation tool shown there is similar in construction and operationto the embodiments described above with several exceptions.

As shown in FIG. 27, the fastener installation tool 460 includes ahandle 461 joined with a frame 462. The frame is joined with a firstfastener guide 480 and a second fastener guide 580. A secondary handle464 is operably joined to the frame 462 and a biasing element 466, aswell as the first fastener guide 480. The secondary handle and biasingelement 466 are adapted to move the first fastener guide 480 asdescribed below.

Turning to FIGS. 27 and 31, the guides 480 and 580 are generallyidentical except reversed at opposite ends of the frame 462. Because thefirst and second guides are identical but simply reversed at oppositeends of the frame, only the first guide will be described here. Theguide 480 is a monolithic structure that defines an angled bore 488 andfurther includes a or otherwise is joined with a spacer 474 that extendsdownwardly from the lower portion of the guide. The guide 480 caninclude a material ejection port 483 that is located between the first484 and second 485 openings of the angled bore 488. The materialejection port can also include a lowermost rim 495 as described in theembodiments above. Further, like the embodiments above, the angled borecan be aligned along an axis 400 along which the fastener 110 can beadvanced in a manner similar to the above embodiments. The guide 480 caninclude a beveled region 482 (FIG. 31) adjacent the first opening 484 toguide the fastener 110 into the angled bore 488. Likewise, the angledbore 488 can be of a length that is less than the length of the fastener110 as described above so that before being installed into a work piece,the top of the head is slightly recessed inward from the outer portionof the guide element to facilitate guiding of a drive feature of a toolinto the head of the fastener 110.

The guide 480 also can include or be joined with a spacer 474 that canbe monolithic with a remainder of the guide. The angled bore 488 canextend downwardly through the spacer 474 so that the spacer 474 definesat least a portion of the angled bore 488. The angled bore 488 canterminate at the second opening 485 which can be defined by the sidesurface 478A of the spacer 474. As with the above embodiments, when thetool is used to install a fastener, this opening and thus the fastenercan be positioned immediately adjacent the side surface 108 of therespective work piece 102.

The guide 480 can define additional apertures 489 (FIG. 30) throughwhich pins 465B can fit to prevent excessive rotational movement of theguide 480 relative to the frame. These pins 465 can also be slidablydisposed in a slots 422, 423 so that the pins can generally guide theguide 480 linearly in the direction of arrow 558.

The guide 480 can operatively be engaged against a portion of thesecondary handle 464 at the handle portion 467. The handle 464 can berotatable about the pivot axis 465. The movement of the handle 464,however can be constrained by the connection bracket 425, which canengage the secondary handle 464, and under the force of the biasingelement 466, urge the handle in the direction 555 as shown in FIG. 28.The connection bracket 425 can be joined via a pin 466A with the biasingelement 466.

The biasing element 466 can be in the form of a coil spring which isjoined to the frame 462 in a relatively fixed location via a pin 466B atone end and is moveable with the pin 466A in the slot 427 at theopposite end thereof. Although shown as a coil spring, the biasingelement 466 can be replaced with a variety of different biasingelements, for example leaf springs, elastomeric materials, pneumaticcylinders, hydraulic cylinders, solenoids, or other elements that canmove the first guide 480 and/or second guide 580 relative to one anotherand/or the frame 462 to clamp or otherwise engage opposing surfaces of awork piece into which a fastener is to be installed within the tool 60.

Returning to FIGS. 27 and 30, the handle 461 can be joined with theframe 462 via a handle frame 420. This handle frame 420 can include anarm that extends upwardly into the handle 461. The handle frame 420 canalso include slots 422 which can align with the slots 423 in the framethrough which the pins 465B can project. The handle frame 422 can befastened to the frame via fasteners such as rivets as illustrated. Ofcourse other fasteners can be used, or the handle and handle frame canbe monolithically formed with the remainder of the frame.

The frame 462 can include feet or tabs 269A and 269B which extendoutward from the lateral sides of the frame a distance sufficient sothat the width of the frame to the outer most portion of the feet onopposing sides is about 1.5 inches, which corresponds to the width of acommon board used as a joist or underlying substructure. Of course, thefeet can extend outward from the sides of the frame other distances, ormay be alternatively folded inward depending on the particularapplication. Indeed, even if desired, the feet may be separate elementssuch as plates that are joined to the bottom of the frame and can extendoutward a preselected distance from the frame depending on the desiredapplication.

As shown in FIGS. 27 and 29, the pins 465B are located through apertures489 in the screw guide 480. Pins 465 are also linearly guided via theirregistration within the slots 422, 423 defined by the handle frame andframe. In operation, the forward portion 467 of the secondary handle 464can engage the pins 465B or the guide 480 itself and push the pinsforward in the slot 422, 423. Accordingly, the guide 480, joined withthe pins 465B moves forward in direction 558. This movement of the guide480 is generally along the linear axis 428. Optionally, to impairrotation of the guide 480 as it moves along in the direction 558, theguide can also be guided directly or indirectly along the second axis429, by the pin 466A sliding in the slot 427, with the connectionbracket 425 rigidly joined with the guide 480 so that the guide 480 doesnot rotate relative to the frame while moving in the direction 558. Avariety of different slots and guide configurations can be substitutedfor those shown to ensure the guide 480 moves linearly in direction 558rather than rotates. Of course, if a pivoting action or rotation of theguide 480 is desired for a certain application, those guides and slotscould be modified to include curvilinear portions or otherwisefacilitate rotation of the guide as desired.

Operation of the installation tool 460 on a work piece 102 will now bedescribed with reference to FIGS. 27 and 28. As shown in FIG. 27, theinstallation tool is initially in a retracted mode shown in solid, butreconfigured to an extended mode shown in phantom, to fit the work piece102. In the retracted mode, the biasing element 466 has urged the guideelement 480 inward toward the other guide element 580 so that thedimension between the spacer 474 and spacer 574 are dimension 570. Toincrease that dimension so the spacers 474 and 575 can fit on opposingsides 108 and 115 of the work piece 102, a user manually grasps thesecondary handle 464 and draws it in the direction 554. The user can dothis simply by squeezing the secondary handle 464 and handle 461together.

The movement of the secondary handle 464 rotates it about the pivot 465in the direction of the arrow 465 a as shown in FIG. 27. In turn, thisengages a portion 467 of the secondary handle 464 against the pins 465Bwhich causes the pins to slide in the slots 422, 423. This moves theguide 480, which is joined with the pins 465B in the direction 558outward from the frame 462. This also moves the first spacer 474 awayfrom the second spacer 479. When the dimension 570 is increased so thatthe spacers 474 and 574 can be positioned and slide downward along thesides 108 and 115 of the work piece, the user may do so. In so doing,the lower surface, and in particular the feet 469A and 469B are engagedagainst the upper surface of the work piece 102. After the feet areengaged against the upper surface and the spacers 474 and 574 have beendisposed in the spaces 105 and 117 immediately adjacent the respectivesides 108 and 115, the user can release the secondary handle 464.

As shown in FIG. 28 this release is shown generally as movement of thehandle 464 in direction 555. When this occurs, the biasing element 466exerts a force 551 on the pins 466A. This pulls the connection bracket425 so that the pin 466A slides in the slot 427, thereby allowing theconnection bracket 425 to pull the guide 480 in the direction 559. Thisprovides a clamping effect between the spacers 474 and 574, which inturn causes the tool to clampingly engage the work piece 102. With thework piece clamped between the spacers, the angled bores 488 and 588 ofthe guides 480 and 580 are aligned along the respective advancementaxes, and the side surfaces of the respective spacers are positionedagainst the respective sides of the work piece. Accordingly, thefasteners can be rotated and advanced in the respective angled bores ofthe respective guides and installed in a manner similar to thatdescribed in the embodiments above. After the fasteners are sufficientlyinstalled, the secondary handle 464 can again be engaged to move thespacer 474 away from the spacer 574 to release the clamp on the workpiece. The tool 460 can then be removed from the work piece. After thetool is removed, another work piece can be installed adjacent the workpiece 102 and the process can be repeated with the tool to installadditional features.

The above clamping mechanism of the tool 460 utilizing the guide 480,the secondary handle 464 and related mechanisms, can provide fineadjustment of the tool to accommodate boards generally of the samenominal dimensions but which may have variations due to quality ofinconsistency of those boards. For example, the adjustment with thehandle 464 can generally adjust the guide 480 and spacers so that thetool accommodates certain boards, for example 5¾″ wide boards that mayhave variation of an ⅛″ to ¼″. In applications where a user may want toswitch to a different job and install a larger board, for example a 6″composite board, the tool optionally can include a more coarseadjustment mechanism 590, which allows the tool to be used withdifferent width or dimensioned boards.

Referring to FIGS. 29-33, one suitable coarse adjustment mechanism 590can include a stopper assembly including first and second stopper pins592A and 592B. The stopper pins can extend through the respective slots595 defined by the frame 462. One or both of the pins can be threaded.As shown in FIG. 32, the upper stopper pin 592 a is threaded and canreceive a wing nut 593 to secure the stopper assembly to the frame in afixed position. The frame itself may define recesses 594 whichaccommodate the dimensions of the wing nut 593 or whatever otherfastener may be used.

The stopper assembly 590 can be prone to rotation due to forces exertedby a work piece on the tool during installation or a clamping actionexecuted by the tool. For example, as shown in FIG. 33, the work piece102 can exert a force 530 on the spacer 574 which can urge the spacer torotate in the direction of the arrow 532 when the tool clamps the workpiece 102. If the guide 580 is allowed to rotate significantly, it canmisalign the spacer 574 with the side surface 115 of the work piece 102,which in turn can misalign the fastener 110 with the side surface 115 ofthe work piece. Accordingly, as the fastener 110 is advanced, it candamage the work piece 102 or otherwise bind in the angled bore of thescrew guide 580. To counter this possible rotation in the direction ofthe arrow 532, or other rotation, the stopper assembly can includetabbed detents 597A that interfit within corresponding detents 597B. Theangle of the upper detents 597A can be such that the free tabs engagethe inner surfaces of the apertures 597B and prevent the stopper fromrotating. Likewise, the lower tabs 598A can be angled inward and can beadapted so that the ends 599C of the tabs engage the flat surfaces ofthe apertures 599D to prevent rotation of the stopper assembly andsubsequently to prevent rotation of the guide 580. There are a varietyof other constructions that can prevent such rotation. Suchconstructions may be readily exchanged with the adjustment element 590described herein.

Although sometimes referred to as boards, the work pieces with which thefasteners and tools herein can be utilized can vary, for example, thework pieces can be composite materials, natural wood, particle board orother suitable building materials.

The above descriptions are those of the preferred embodiments of theinvention. Various alterations and changes can be made without departingfrom the spirit and broader aspects of the invention as defined in theappended claims, which are to be interpreted in accordance with theprinciples of patent law including the doctrine of equivalents. Anyreferences to claim elements in the singular, for example, using thearticles “a,” “an,” “the,” or “said,” is not to be construed as limitingthe element to the singular. Any reference to claim elements as “atleast one of X, Y and Z” is meant to include any one of X, Y or Zindividually, and any combination of X, Y and Z, for example, X, Y, Z;X, Y; X, Z; and Y, Z.

1. A tool to install a fastener through the side of a first work pieceand into a second work piece, the tool comprising: a frame including abottom surface adapted to be positioned adjacent a first work piece, thefirst work piece including a side surface, a bottom surface disposed atan angle to the first surface, a top surface opposite the bottomsurface, and a space adjacent the side surface; a handle joined with theframe and adapted to be grasped by a user; a first guide joined with theframe, the first guide defining an angled bore, the angled boreincluding an axis, a first opening adapted to enable a fastener to enterthe angled bore and a second opening adapted to enable the fastener toexit the angled bore, the first and second openings aligned along theaxis, the axis adapted to be disposed at a preselected, non-orthogonalangle relative to the side surface of the work piece; and a first spacerjoined with the first guide, the first spacer projecting downwardly fromthe first guide a distance and adapted to extend into the space adjacentthe side surface, the first spacer defining at least a portion of theangled bore so that the first spacer locates the second openingimmediately adjacent the side surface of the first work piece, whereinthe angled bore is adapted to guide a fastener as the fastener isrotated therein and as the fastener is advanced along the axis throughthe side surface and the bottom surface of the first work piece, andsubsequently into a second work piece adjacent the bottom surface,wherein the angled bore includes a first material ejection port locatedbetween the first opening and the second opening, the first materialejection port adapted to eject material augered up the angled bore fromthe first work piece by the fastener, whereby the fastener can rotate inthe angled bore without the rotation being substantially impaired by thematerial and whereby the first material ejection port can eject thematerial so that the amount of material pulled back into the work pieceby a head of the fastener is reduced.
 2. The tool of claim 1 wherein thefirst spacer is of a width corresponding to a preselected spacingbetween the side surface of the first work piece and a third work piecepositioned atop the second work piece and near the side surface.
 3. Thetool of claim 1 comprising a clamp assembly joined with the frame, theclamp assembly including a second spacer located a distance from thefirst spacer, the clamp assembly adapted to move at least one of thefirst spacer and the second spacer relative to the other to clamp thefirst work piece and thereby hold the angled bore in a preselectedorientation relative to the first work piece.
 4. The tool of claim 3comprising a secondary handle moveably joined with the frame, thesecondary handle adapted to actuate the clamp assembly and move at leastone of the first spacer and the second spacer relative to the other. 5.The tool of claim 1 comprising a second spacer joined with the frame andlocated a distance from the first spacer, wherein at least one of thefirst spacer and the second spacer moves relative to the other to changethe distance therebetween.
 6. The tool of claim 1 wherein the angledbore is of a preselected length equal to or greater than the length ofthe fastener.
 7. The tool of claim 1 comprising a biasing element joinedwith the first spacer, the biasing element adapted to selectively movethe first spacer into engagement with the side surface of the first workpiece.
 8. The tool of claim 1 comprising a second spacer joined with theframe and a biasing element joined with the second spacer, the biasingelement adapted to selectively move the second spacer relative to thefirst spacer.
 9. The tool of claim 8 comprising a secondary handlejoined with the biasing element, the biasing element urging the secondspacer to move away from the first spacer, the secondary handleconfigured to enable a user to manually counter the biasing element andmove the second spacer toward the first spacer, whereby the first andsecond spacers cooperatively clamp the first work piece therebetween.10. The tool of claim 1 wherein the material ejection port includes anedge, the edge being positioned adjacent the fastener as the fastener isrotated, wherein the edge forms a wiping surface to remove material fromthreads of the fastener.
 11. A tool to install a fastener through afirst work piece and into a second work piece, the tool comprising: aframe including a frame surface adapted to be positioned adjacent afirst work piece, the first work piece including a first surface, asecond surface disposed at an angle to the first surface, a spaceadjacent the first surface, a third surface disposed on an opposite sideof the first work piece from the second surface, and a fourth surfacedisposed on an opposite side of the first work piece opposite the firstsurface, the frame adapted to be positioned adjacent the third surface,generally atop the work piece; a handle joined with the frame andadapted to be grasped by a user; a first guide joined with the frame,the first guide defining an angled bore, the angled bore including anaxis, a first opening adapted to enable a fastener to enter the angledbore and a second opening adapted to enable the fastener to exit theangled bore, the first and second openings aligned along the axis, theangled bore extending from above the third surface into the space andadjacent the first surface so that the second opening opens immediatelyadjacent the first surface of the first work piece; and a clamp assemblyjoined with the frame including a clamp element, the clamp elementpositioned a distance from the second opening, the clamp assemblyadapted to move at least one of the clamp element and the frame toclampingly engage the first and fourth opposing surfaces of the firstwork piece and hold the second opening immediately adjacent the firstsurface, wherein the first guide is adapted to guide a fastener as thefastener is rotated and advanced through the angled bore, with thefastener being steadily held in alignment with the first surface andwith the axis as the fastener advances into the first work piece andinto the second work piece to join the first work piece and the secondwork piece.
 12. The tool of claim 11 wherein the angled bore is of apreselected length so that a fastener positioned in the angled bore andengaging the first work piece, before the fastener penetrates the firstsurface, is substantially entirely enclosed within the angled bore. 13.The tool of claim 11 wherein the first guide includes an entrancesurface that surrounds the first opening, wherein the fastener includesa head, wherein the head is positioned in the angled bore a distanceinward from the entrance surface before the fastener penetrates thefirst surface, whereby a tool can be guided by at least a portion of theangled bore and entrance surface to center the tool for engagement withthe head.
 14. The tool of claim 11 wherein the first guide includes afirst spacer, the first spacer defining at least a portion of the angledbore so that the second opening is defined by the first spacer, whereinthe first spacer is joined with the frame so that the first spacer ispositioned adjacent the first surface in the space, wherein the firstspacer is of a predetermined thickness corresponding to spacing betweenthe first work piece and an adjacent third work piece.
 15. The tool ofclaim 14 wherein the clamp element is a second spacer that is positionedon an opposite end of the frame a distance from the first spacer,wherein the distance is greater than the width of the first work piece.16. The tool of claim 15 comprising a second guide joined with theframe, wherein the second guide includes the second spacer, wherein thesecond guide defines another angled bore that opens immediately adjacentthe fourth surface of the first work piece opposite the first surface,whereby another fastener can be rotated and advanced through the otherangled bore and into the first and second work pieces.
 17. The tool ofclaim 11 wherein the handle is operatively joined with the clampelement, wherein the handle is moveable and adapted to actuate the clampassembly so that the clamp element and first spacer move relative to oneanother to clamp the first work piece.
 18. The tool of claim 11comprising a material ejection port defined by at least one of the firstguide and the frame, the material ejection port located entirely abovethe third surface so that material ejected from the material ejectionport ejects substantially only from the port above the third surface ofthe work piece.
 19. The tool of claim 11 wherein the material ejectionport includes a lowermost rim, distal from the first opening and thesecond opening of the angled bore, wherein the lowermost rim is locatedabove the third surface.
 20. A tool to install a fastener through aboard and into an underlying joist, the tool comprising: a frame; ahandle joined with the frame; a guide including a first spacer thatextends downwardly a distance from a bottom of the frame, the firstspacer adapted to occupy a space adjacent a first side of a first board,the first spacer adapted to establish a predefined spacing between theboard and another board placed adjacent the board, the guide defining anangled bore extending along an axis adapted to be placed at anon-orthogonal angle relative to the first side of the first board whenthe frame is placed atop the first board, the angled bore including afirst opening adapted to enable a fastener to enter the angled bore anda second opening adapted to enable the fastener to exit the angled boreadjacent the first side of the first board, the angled bore including afirst material ejection port located between the first opening and thesecond opening, the angled bore sized to enable a rotating fastener toadvance through the angled bore; a clamp assembly joined with the frameincluding a clamp element, the clamp element positioned a distance fromthe second opening, the clamp assembly adapted to clampingly engage thefirst side of the first board and another side of the first boardopposite the first side of the first board, and hold the second openingimmediately adjacent the first side of the first board, wherein theguide is adapted to guide a fastener as the fastener is rotated andadvanced through the angled bore, holding the fastener in alignment withthe first side of the first board and the axis as the fastener advancesinto the first board and into the underlying joist to join the firstboard with the underlying joist.
 21. A method of installing a fastenerwith a tool to join work pieces, the method comprising: providing afirst work piece including a top surface, a bottom surface opposite thetop surface and substantially parallel to the top surface, and first andsecond side surfaces joined with the top surface and the bottom surface,the first and second side surfaces being substantially perpendicular tothe top and bottom surfaces, the first and second side surfaces beingpositioned on opposite sides of the first work piece; placing the bottomsurface of the first work piece over a second work piece; providing atool including a first spacer that extends downwardly and is adapted tooccupy a first space adjacent the first side surface of the first workpiece, a second spacer that extends downwardly and is adapted to occupya second space adjacent the second side surface of the first work piece,the tool including a guide defining an angled bore extending along anaxis adapted to be placed at a non-orthogonal angle relative to thefirst side surface of the first work piece, the angled bore including afirst opening adapted to enable a fastener to enter the angled bore anda second opening adapted to enable the fastener to exit the angled boreimmediately adjacent the first side surface of the first work piece;placing the frame of the tool atop the top surface of the first workpiece so that the first spacer extends downwardly into the first spaceadjacent the first side surface of the first work piece, so that thesecond spacer extends downwardly into the second space adjacent thesecond side surface of the first work piece, and so that the secondopening is immediately adjacent the first side surface of the workpiece, with the angled bore disposed at the non-orthogonal anglerelative to the first side surface of the work piece; moving at leastone of the first spacer and the second spacer toward the other of thefirst spacer and the second spacer to clamp the first work piecetherebetween, with the first spacer engaging the first side surface andthe second spacer engaging the second side surface; rotating thefastener within the angled bore; and advancing the fastener along theaxis of the angled bore so that the fastener enters the first sidesurface immediately after exiting the second opening, the fasteneradvancing at least partially through the first work piece and into thesecond work piece to join the first work piece and the second workpiece.
 22. The method of claim 21 comprising pre-boring a hole with thefastener along the axis so that material from the first work piece isfed into the angled bore by threads of the fastener.
 23. The method ofclaim 22 wherein the guide defines a material ejection port incommunication with the angled bore, the material ejection port beinglocated between the first opening and the second opening and comprisingejecting the material from the angled bore out the material ejectionport, whereby the amount of material pulled back into the work piece bya head of the fastener is reduced.
 24. The method of claim 21 whereinthe first spacer includes a spacer side surface, wherein the spacer sidesurface defines the second opening, wherein the spacer side surfaceengages the first side surface of the first work piece during saidclamping step, and wherein the spacer is dimensioned to establishspacing between the first work piece and a third work piece.
 25. Themethod of claim 21 comprising: boring material from a hole in the firstwork piece with the fastener; feeding the material into the angled bore;and ejecting the material from the angled bore between the first openingand the second opening, whereby the ejecting of the material reduces theamount of material pulled back into the work piece by a fastener head toreduce the potential for damaging the first work piece in the areasurrounding the fastener.
 26. The method of claim 25 comprising:positioning a third work piece adjacent the first work piece; moving thetool to a position atop a top surface of the third work piece so that atleast one of the first spacer and the second spacer establishes apreselected spacing between the first work piece and the third workpiece; rotating a second fastener within the angled bore; and advancingthe second fastener along the axis of the angled bore so that the secondfastener enters the third work piece, travelling at least partiallythrough the third work piece and into the second work piece to join thethird work piece and the second work piece, whereby the third work piecelays adjacent the first work piece and atop the second work piece. 27.The method of claim 26 comprising clamping the third work piece betweenthe first spacer and the second spacer so that the second opening ispositioned immediately adjacent a side surface of the third work piece.28. A method of installing a board on a joist, the method comprising:providing a board including a top, a bottom opposite the top andparallel to the top, and first and second sides positioned on oppositesides of the board; placing the board on a joist; placing a tool atopthe top of the board, the tool defining an angled bore extending alongan axis adapted to be placed at a non-orthogonal angle relative to thefirst side of the board, the angled bore including a first openingadapted to enable a fastener to enter the angled bore and a secondopening adapted to enable the fastener to exit the angled boreimmediately adjacent the first side of the board, the angled boreincluding a material ejection port located between the first opening andthe second opening; inserting in the angled bore a fastener including athread, rotating the fastener so that the fastener advances through thesecond opening and into the board, pre-boring a hole with the fastenerin the board, the fastener augering material from the board through thesecond opening and into the angled bore; ejecting the augered materialfrom the angled bore through the material ejection port; and continuingto advance the fastener through the bottom surface of the board and intothe underlying joist, whereby the board is joined with the underlyingjoist.
 29. The method of claim 28 wherein the fastener includes a shaftaround which the thread coils, the thread terminating adjacent a chiseledge, wherein the fastener augers material along the thread during saidpre-boring step toward the material ejection port.
 30. The method ofclaim 28 wherein the guide includes a first spacer and comprisingplacing the first spacer so that it extends downwardly and occupies afirst space adjacent the first side of the board before said pre-boringstep.
 31. The method of claim 28 wherein the threads are configured tofeed the fastener at a theoretical feed rate, comprising: retardingadvancement of the fastener in the board to a second feed rate that isless than the theoretical feed rate for a preselected distance; andovercoming the retarding of the advancement of the fastener by engagingthe threads with the pre-bored hole so that the fastener advances at athird feed rate that is greater than the second feed rate.
 32. Themethod of claim 28 wherein the material ejection port includes alowermost rim located above the top surface of the board, wherein thematerial is ejected above the top surface of the board.
 33. The methodof claim 28 wherein the tool includes a clamping assembly, comprisingclampingly engaging the first and second sides of the board with theclamping assembly to steadily position the second opening immediatelyadjacent the first side surface of the board, wherein the clampingassembly clampingly engages the first and second sides of the board asthe fastener is rotated.
 34. The method of claim 29 wherein chisel edgeis formed at the intersection of a first inclined surface and a secondinclined surface, wherein the first inclined surface and the secondinclined surface are at an angle of about 85° to about 150° relative toone another, whereby the angle enables the chisel edge to selectivelyretard advancement of the fastener into the board.
 35. A method ofinstalling a fastener with a tool to join work pieces, the methodcomprising: providing a first work piece including a top surface, abottom surface opposite the top surface, and first and second sidesurfaces joined with the top surface and the bottom surface on oppositesides of the first work piece; placing the bottom surface of the firstwork piece adjacent a second work piece; providing a tool including aguide defining an angled bore extending along an axis, the angled boreincluding a first opening and a second opening; placing the axis at anon-orthogonal angle relative to the first side surface of the firstwork piece, with the second opening positioned immediately adjacent thefirst side surface of the first work piece; inserting in the angled borea fastener including a thread; rotating the fastener so that thefastener advances through the second opening and the first side surfaceof the work piece; pre-boring a hole with the fastener in the first workpiece, the fastener augering material from the first work piece throughthe second opening and into the angled bore; ejecting the augeredmaterial from the angled bore; and continuing to advance the fastenerthrough the bottom surface of the first work piece and into the secondwork piece, whereby the first work piece is joined with the second workpiece.
 36. The method of claim 35 wherein the tool includes a clampingassembly, comprising clamping the first and second side surfaces of thefirst work piece with the clamping assembly to steadily hold the secondopening immediately adjacent the first side surface of the work piece,wherein the angled bore rotationally constrains the fastener to inhibitthe fastener from at least one of wandering and wobbling as the fastenerbegins to penetrate the first side surface of the work piece.
 37. Themethod of claim 35 wherein the fastener includes a shaft around whichthe thread coils, the thread terminating adjacent a chisel edge, whereinthe fastener augers material along the thread during said pre-boringstep.
 38. The method of claim 35 wherein the angled bore includes amaterial ejection port located between the first opening and the secondopening, wherein the augered material is ejected from the angled borethrough the material ejection port thereby reducing the amount ofaugered material pulled back into the work piece by a head of thefastener, whereby the likelihood of damage to the work piece adjacentthe installed fastener is reduced.
 39. The method of claim 35 whereinthe fastener includes threads configured to feed the fastener at atheoretical feed rate and comprising retarding advancement of thefastener in the first work piece to a second feed rate that is less thanthe theoretical feed rate for a preselected distance.
 40. The method ofclaim 35 wherein the fastener includes a chisel brake point having afirst inclined surface and a second inclined surface, wherein the firstinclined surface and the second inclined surface are at an angle ofabout 85° to about 150° relative to one another, wherein the chiselbrake point selectively retards advancement of the fastener into theboard.